Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUSES AND METHODS FOR GENERATING A HIGH-
CONCENTRATION PROTEIN PRODUCT FROM A BLANCHED BIOMASS
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to the provisional filing U.S., Application
No.
62/216,975 filed September 10, 2015, the contents of which are hereby
incorporated in their
entirety by reference. Applicants also incorporate herein by reference the
contents of
concurrently filed Application No. 15/263,253 in their entirety.
FIELD OF THE DISCLOSURE
The present disclosure relates, in some embodiments, to apparatuses and
methods for
blanching a microcrop (e.g., aquatic species, Lemna, Wolffia) and a protein
product (e.g.,
high-concentration protein product) derived therefrom. In some embodiments,
the present
disclosure relates to apparatuses and methods for continuously blanching a
microcrop and
producing a protein product (e.g., high-concentration protein product) derived
therefrom.
BACKGROUND OF THE DISCLOSURE
An ever-increasing global population continues to fuel a plethora of
sustainability
concerns including sufficient and affordable access to protein sources for
both feed animals
and human consumption, particularly in developing nations. While marine
protein sources
are often utilized in feeds due to their desirable nutritional profile and
enhanced palatability,
high production costs lead to an increased demand for alternatives. However,
many plant
species are unsuitable alternatives due to qualities such as inferior amino
acid profile, inferior
protein quality and/or quantity, inferior digestibility, high fiber content,
and/or high oxalic
acid content. Moreover, some protein sources pose significant allergy concerns
to certain
consumers (e.g., soy, dairy). Microcrop species (e.g., Lemna, Spirodella,
Wolffia) that are
properly blanched and processed yield protein preparations with many desirable
qualities.
However, biological characteristics of these microcrop species (e.g., Lemna)
pose production
and quality challenges. For example, many microcrop species grow as free-
floating thalli on
a surface of a growth medium. Such buoyancy of a microcrop species presents
unique
challenges in achieving a uniform blanching
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Additionally, water conservation concerns¨particularly in equatorial and arid
regions¨are a driving factor in identifying suitable apparatuses and methods
for producing
high concentration protein products from microcrop species. Moreover, energy
efficiency is
also an important consideration, as the production of high-concentration
protein products
from microcrop species has enormous potential for alleviating protein
shortages in
developing economic regions.
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SUMMARY
Accordingly, a need has arisen for improved apparatuses and methods for
blanching
(e.g., continuously) a microcrop (e.g., aquatic species, Lemna) and a protein
product (e.g.,
high-concentration protein product) derived therefrom.
The present disclosure relates, according to some embodiments, to an apparatus
for
blanching a microcrop (e.g., Lemna, Wolf:11a) where the apparatus may include:
a conveyance
mechanism operable to transport a biomass to a blanching tray; an applicator
operable to
dispense a blanching solution onto at least one surface of the biomass within
the blanching
tray; the blanching tray oriented to receive a volume of the blanching
solution from the
applicator; and a vibratory mechanism capable of vibrating the blanching tray
to generate a
net motion of the received volume of the blanching solution within blanching
tray such that a
wave of blanching solution is formed. In some embodiments, a vibratory
mechanism may be
operable to generate a motive force capable of directing a biomass from a
first side of a
blanching tray to a second side of the blanching tray. In some embodiments, an
apparatus
may be capable of processing a biomass at a product flow rate ratio of about
7:1 (e.g., w/w,
blanching solution: biomass).
In some embodiments, an apparatus may further include at least one of: a
central
control system operable to communicate with one or more elements of the
apparatus; a
heating element capable of heating a blanching solution to a temperature of at
least 60 C;
and a pump and valve system operable to propel the blanching solution within
the apparatus.
An apparatus, in some embodiments, may include a first gauge. A first gauge
may be
operable to measure at least one of: a volume of blanching solution received
within a
blanching tray; a mass of a biomass within the blanching tray; a volume of a
blanching
solution exiting a blanching tray, a mass of a biomass exiting a blanching
tray, a temperature
of a blanching solution within a blanching tray, a temperature of a blanching
solution exiting
the blanching tray, and a rate of a net motion. According to some embodiments,
a first gauge
may be capable of communicating with at least one of: a central control
system, a heating
element, a pump and valve system, a shower, and a vibratory mechanism and any
combination thereof.
An apparatus for blanching a microcrop (e.g., Lemna, Wolf:11a), in some
embodiments,
may include a settling tank connected to the blanching tray such that a
blanched biomass may
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flow from the blanching tray into the settling tank. A settling tank may
comprise at least one
sloping surface, according to some embodiments. In some embodiments, an
apparatus for
blanching a microcrop may include a rinsing mechanism connected to a settling
tank such
that a blanched biomass may flow from the settling tank into the rinsing
mechanism.
According to some embodiments, an apparatus for blanching a microcrop (e.g.,
Lemna, Wolffia) may include a dewatering mechanism (e.g., screw press,
vibratory screen,
both) connected to the blanching tray such that the blanched biomass is
capable of flowing
from the blanching tray into the dewatering mechanism. In some embodiments, a
dewatering
mechanism may be connected to a settling tank such that a blanched biomass may
be capable
of flowing from the settling tank into the dewatering mechanism.
The present disclosure further relates to a method of processing a biomass to
generate
a protein product (e.g., high-concentration protein product), where the method
may include:
contacting a first portion of the biomass with a first volume of blanching
solution to generate
a first blanched biomass, dewatering the first portion of the blanched biomass
(e.g., using a
screw press) to generate a separated solution; and drying the first blanched
biomass to
generate at least one of a first protein concentrate flake and a first protein
concentrate
granule. In some embodiments, contacting a first portion of a biomass may
include at least
one of applying a first volume of blanching solution to at least one surface
of the first portion
of the biomass and submerging the first portion of the biomass in a wave of
blanching
solution. According to some embodiments, a first volume of blanching solution
may have a
temperature of at least 60 C. In some embodiments, contacting a first portion
of a biomass
may be performed at a product flow rate ratio selected from: about 8:1, or
about 7.5:1, or
about 7:1, or about 6.5:1, or about 6:1, or about 5.5:1, or about 5:1, or
about 4.5:1, or about
4:1. According to some embodiments, at least one of the first protein
concentrate flake and
the first protein concentrate granule comprises at least 45% protein, the
protein having a
Protein Digestibility Corrected Amino Acid Score (PDCASS) value of at least
0.88.
Contacting, in some embodiments, may be for a period of less than 2 minutes
(e.g.,
about 45 sec). According to some embodiments, contacting may be for a period
of less than
2 min where a first volume of blanching solution may have a temperature
between about 750
C and 95 C. In some embodiments, a first volume of blanching solution may
have a
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temperature of at least 85 C. A first volume of blanching solution, in some
embodiments,
may comprises at least one calcium salt.
In some embodiments, a method may include washing a first portion of the
biomass
with at least one of a first wash solution, a second wash solution, and a
third wash solution,
where the first wash solution, the second wash solution, and the third wash
solution may be
independently selected from a water, a recycled fluid, and an ozonated
solution. A method of
processing a biomass to generate a protein product (e.g., high-concentration
protein product),
in some embodiments, may further comprising milling at least one of a first
protein
concentrate flake and a first protein concentrate granule to generate a first
protein concentrate
flour. In some embodiments, a method may further comprise settling a blanched
biomass in a
settling solution.
According to some embodiments, a method of processing a biomass comprising a
microcrop may include solvent extracting a first portion of the blanched
biomass. In some
embodiments, a wet protein concentrate may be separated from a separated
solution using a
vibratory screen (e.g., before solvent extraction).
A method of processing a biomass comprising a microcrop may include recycling
a
separated solution by performing at least one of: diluting the separated
solution, filtering the
separated solution, and monitoring the separated solution. In some
embodiments, a method
may include contacting a second portion of the biomass with a second volume of
blanching
solution or a recycled blanching solution to generate a second blanched
biomass; dewatering
the second blanched biomass to generate the separated solution; and drying the
second
blanched biomass to generate at least one of a second protein concentrate
flake and a second
protein concentrate granule. At least one of a second protein concentrate
flake and a second
protein concentrate granule may comprises at least 45% protein, the protein
having a
PDCASS value of at least 0.88.
The present disclosure relates, in some embodiments to a method of
continuously
blanching a biomass (e.g., Lemna, Wolffia) to generate a high-concentrations
protein product,
the method comprising: contacting a first portion of the biomass with a
blanching solution to
generate a first blanched biomass; dewatering the first blanched biomass
(e.g., using a screw
press) to generate a separated solution; collecting the separated solution;
contacting a second
portion of the biomass with the separated solution to generate a second
blanched biomass;
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dewatering the second portion of the biomass to generate the separated
solution; and drying at
least one of the first blanched biomass and the second blanched biomass to
generate at least
one of a protein concentrate flake and a protein concentrate granule.
Contacting a first
portion of a biomass or a second portion of a biomass, according to some
embodiments at
least one of: applying a first volume of blanching solution, a second volume
of blanching
solution, or a recycled blanching solution to at least one surface of the
biomass (e.g., first
portion, second portion) and submerging the biomass in a wave of blanching
solution.
According to some embodiments, a blanching solution may have a temperature of
at least 60
C. In some embodiments, contacting a biomass (e.g., first portion, second
portion) may be
performed at a product flow rate ratio selected from: about 8:1, or about
7.5:1, or about 7:1,
or about 6.5:1, or about 6:1, or about 5.5:1, or about 5:1, or about 4.5:1, or
about 4:1.
Contacting, in some embodiments, may be for a period of less than 2 minutes
(e.g., about 45
sec). According to some embodiments, contacting may be for a period of less
than 2 min
where a first volume of blanching solution may have a temperature between
about 75 C and
95 C. In some embodiments, a first volume of blanching solution may have a
temperature of
at least 85 C. A first volume of blanching solution, in some embodiments, may
comprises at
least one calcium salt.
According to some embodiments, at least one of the first protein concentrate
flake and
the first protein concentrate granule comprises at least 45% DMB protein, the
protein having
a Protein Digestibility Corrected Amino Acid Score (PDCASS) value of at least
0.88.
In some embodiments, a method may include diluting a separated solution. A
method, in some embodiments, may further comprise settling a first blanched
biomass, or the
second blanched biomass, or both in a settling solution. According to some
embodiments, a
method may include milling at least one of a protein concentrate flake and a
protein
concentrate granule to generate a protein concentrate flour.
A method, in some embodiments, may further comprise cultivating a microcrop in
a
first medium comprising at least one of an antiphotosynthetic dye and a
calcium composition
of at least 100 ppm; and harvesting the microcrop to generate the biomass. In
some
embodiments, a method may include soaking a biomass in a second medium, where
the
second medium comprises less than about 8 ppm of a calcium source, or less
than about 4
ppm of a nitrogen source, or both.
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In some embodiments, a method may include solvent extracting a first blanched
biomass, or a second blanched biomass, or both. A vibratory screen may be used
to dewater
a first blanched biomass, a second blanched biomass, or both prior to solvent
extracting. In
some embodiments, a method may include dewatering a first blanched biomass, a
second
blanched biomass, or both after solvent extracting, where the dewatering is
performed using a
screw press.
The present disclosure further relates, in some embodiments, to a protein
product
(e.g., high-concentration protein product) generated by processing a biomass
comprising a
microcrop, by a method described herein to generate at least one of a first
protein concentrate
flake and a first protein concentrate granule. At least one of a first protein
concentrate flake
and a first protein concentrate granule may comprise at least 45% protein, the
protein having
a PDCASS value of at least 0.88. In some embodiments, the PDCASS value may be
limited
by histidine.
In some embodiments, at least one of a first protein concentrate flake and a
first
protein concentrate granule may include at least one of following
characteristics: the protein
may have a PDCASS value of at least 0.92, a digestibility of at least 90%, an
ash content of
less than 10% DMB, a dietary fiber content of at least 30%, an oxalic acid
content of less
than 1% DMB, and a polyphenol content of less of less than 3.2 mg/100 g.
According to
some embodiments, at least one of a first protein concentrate flake and a
first protein
concentrate granule may comprise an oxalic acid content of less than 0.25%
DMB, a
polyphenol content of less of less than 1.75 mg/100 g, or both.
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BRIEF DESCRIPTION OF THE DRAWINGS
The file of this patent contains at least one drawing executed in color.
Copies of this
patent with color drawing(s) will be provided by the Patent and Trademark
Office upon
request and payment of the necessary fee.
Some embodiments of the disclosure may be understood by referring, in part, to
the
present disclosure and the accompanying drawings, wherein:
FIGURE 1 illustrates an apparatus capable of blanching a biomass, according to
a
specific example embodiment of the disclosure;
FIGURE 2 illustrates an apparatus capable of blanching a biomass, according to
a
specific example embodiment of the disclosure;
FIGURE 3 is a flow diagram illustrating a process for cultivating, harvesting,
and
processing a microcrop for the production of high-concentration protein
product according to
a specific example embodiment of the disclosure;
FIGURE 3A is a flow diagram illustrating a process for blanching a microcrop
for the
production of high-concentration protein product according to a specific
example
embodiment of the disclosure; and
FIGURE 4 is a flow diagram illustrating a process for cultivating, harvesting,
and
processing a microcrop for the production of high-concentration protein
product according to
a specific example embodiment of the disclosure.
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DETAILED DESCRIPTION
The present disclosure relates, in some embodiments, to methods and
apparatuses for
blanching (e.g., continuously) a microcrop to generate a high concentration
protein product.
According to some embodiments, the present disclosure relates to high
concentration protein
products derived using a method or apparatus for blanching (e.g.,
continuously) a microcrop
(e.g., Lemna).
Microcrop
In some embodiments, a microcrop may comprise a single aquatic species (e.g.,
Lemna species, Salvinia species). A microcrop may include species of Lemna
(e.g.,
duckweed), Spirodela, Landoltia, Wolfiella, Salvinia (e.g., floating fern),
Wollfia (e.g.,
watermeal), Azolla (e.g., mosquito fern), Pistia (e.g., water lettuce), or any
combination
thereof According to some embodiments, a microcrop may be a species of Lemna,
for
example, Lemna minor, Lemna obscura, Lemna minuta, Lemna gibba, Lemna
valdiviana, or
Lemna aequinoctialis. A microcrop may comprise, according to some embodiments,
a
combination of two or more aquatic species. In some embodiments, a microcrop
may be
selected from a local aquatic species based on identified compositional and
growth
characteristics that have developed within the local environmental conditions.
Local species
may out-compete other species in open ponds or bioreactors based on their
adaptation to the
local environmental conditions. A microcrop, in some embodiments, may be
adjusted in
response to seasonal variations in temperature and light availability.
A microcrop may have characteristics that are advantageous in comparison to
other
aquatic species (e.g., rapid growth rate; reduced nutritional requirements;
ease of harvesting
and/or processing; enhanced amino acid profile; enhanced palatability; reduced
evapotranspiration rate; increased protein composition).
For example, Lemna is a genus of free-floating aquatic plants from the
Lemnaceae
family (e.g., duckweed) that grow rapidly. Lemna protein has an essential
amino acid profile
that more closely resembles animal protein than most other plant proteins.
Table 1 shows a
typical essential amino acid compositional profile of Lemna protein.
Additionally, Lemna
provides high protein yields, with freshly harvested Lemna containing up to
about 43%
protein by dry weight. Furthermore, compared with most other plants, Lemna
leaves have a
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low fiber content (e.g., about 5% - about 15% in dry matter) and are highly
digestible, even
for monogastric animals. This contrasts with the compositions of many crop
species (e.g.,
soy beans, rice, maize) which have fiber contents of approximately 50% and low
digestibility.
TABLE 1: Essential Amino Acid Profile of Lemna Protein Concentration
Essential Amino Acid Protein (g/ 100 g)
Lysine 5.9
Leucine 9.7
Isoleucine 5.1
Methionine 2.4
Phenylalanine 6.3
Threonine 4.4
Tryptophan 2.0
Valine 6.3
Histidine 2.7
Arginine 6.8
Processing a microcrop (e.g., Lemna) may generate a high-protein concentrate
product
having improved qualities and/or compositions relative to an unprocessed
microcrop product
(e.g., superior protein content, superior PDCASS value, superior
digestibility, superior amino
acid profile, desired fiber content, and/or reduced oxalic acid content). In
some embodiments
of the present disclosure, processing a microcrop may include blanching a
microcrop.
APPARATUSES FOR BLANCHING A MICROCROP
FIGURES 1 and 2 illustrate example embodiments of apparatuses 100/200 for
blanching (e.g., continuously blanching) a microcrop, according to some
embodiments of the
present disclosure. According to some embodiments, a biomass 104/204 may move
(e.g., by
conveyance, by gravity, by liquid flow) through an apparatus 100/200 at a
product flow rate
ratio calculated by dividing a pump rate by a feed rate. For example, an
apparatus 100/200
performing at a pump rate of 28 liters per min (L/min) and a feed rate of 4 kg
per min
(kg/min) results in a product flow rate ratio of 7:1. According to some
embodiments, an
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apparatus 100/200 may have a product flow rate ratio of about 10:1, or about
9:1, or about
8:1, or about 7.5:1, or about 7:1, or about 6.5:1, or about 6:1, or about
5.5:1, or about 5:1, or
about 4.5:1, or about 4:1, or about 3.5:1, or about 3:1, or about 2.5:1, or
about 2:1, or about
1.5:1, or about 1:1, according to some embodiments. According to some
embodiments, an
apparatus 100/200 may include a central control system 102/202 operable to
communicate
with one or more elements of the apparatus, monitor one or more conditions
(e.g., product
flow ratio), and implement adjustments. In some embodiments, a central control
system
may be a programmable logic controller. A central control system 102/202, in
some
embodiments, may communicate with a first gauge (e.g., FIGURE 2 222), a second
gauge
(e.g., FIGURE 2 229), a collection tank gauge (e.g., FIGURE 2 238), a pump and
valve
system (e.g., FIGURE 2 248), or any combination thereof In some embodiments, a
central
control system 102/202 may be operable to maintain and/or adjust a product
flow rate (e.g.,
7:1), a feed rate, a pump rate, or any combination thereof
As shown in FIGURES 1 and 2, apparatuses 100/200 for blanching a microcrop may
include a conveyance mechanism 116/216 and a blanching tray 117/217. According
to some
embodiments, conveyance mechanism 116/216 may be operable to transport a
biomass (e.g.,
a harvested microcrop, a washed biomass) 104/204 to blanching tray 117/217.
Conveyance
mechanism 116/216, in some embodiments, may include any mechanism of
transporting
biomass 104/204 (e.g., Lemna) to blanching tray 218. For example, conveyance
mechanism
116/216 may comprise a conveyor belt or series of conveyor belts, in some
embodiments. In
some embodiments, conveyance mechanism 116/216 may include a slide or chute
wherein
biomass 104/204 enters blanching tray 117/217 at least in part due to
gravitational forces.
In some embodiments, a biomass 104/204 may be transported to blanching tray
117/217 at a feed rate. A feed rate may be regulated based on an overall size
of an apparatus
100/200 and/or a pump rate to maintain a desired product flow rate ratio
(e.g., 7:1), according
to some embodiments. A feed rate, in some embodiments, may be about 0.5
kg/min, or about
1 kg/min, or about 1.5 kg/min, or about 2 kg/min, or about 3 kg/min, or about
4 kg/min, or
about 5 kg/min, or about 10 kg/min, or about 20 kg/min, or about 50 kg/min, or
about 100
kg/min, or about 150 kg/min, or about 200 kg/min, or about 250 kg/min, or
about 300
kg/min, or about 350 kg/min, or about 400 kg/min.
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As shown in FIGURES 1 and 2, an apparatus 100/200, in some embodiments, may
include a source 110/210 operable to provide a blanching solution 106/206 to
one or more
elements of apparatus 100/200. A source 110/210, in some embodiments, may
include a
holding tank, a well, a water line, or any other container or system capable
of holding and/or
transporting a liquid. According to some embodiments, a source 110/210 may
contain and/or
transport a blanching solution 106/206 comprised of water, ground water, well
water,
distilled water, deionized water, reverse osmosis water, nanofiltered water,
ultra-filtered
water, or any combination thereof In some embodiments, a source 110/210 may
contain
and/or transport a blanching solution 106/206 comprising at least one
dissolved solid (e.g.,
ash). A source 110/210, in some embodiments, may contain and/or transport a
blanching
solution 106/206 comprising calcium salt (e.g., calcium chloride, calcium
acetate). In some
embodiments, a source 110/210 may contain and/or transport a blanching
solution 106/206
which was exposed to a microcrop, collected, and re-used (e.g., a recycled
blanching solution
(e.g., FIGURE 2 235)).
As shown in FIGURES 1 and 2, in some embodiments, apparatus 100/200 may
include a piping system 111/211. Piping system 111/211 directly or indirectly
connect
various components of apparatus 100/200 to one another and provide a conduit
through
which a liquid (e.g., blanching solution, a separated solution, a settling
solution) may travel.
For example, piping system 111/211 may be directly or indirectly connect
source 110/210 to
an applicator 114/214 (e.g., shower) such that blanching solution 106/206 may
travel from
source to applicator. In some embodiments, piping system 111/211 may be
composed of
metal (e.g., steel, stainless steel, copper, lead), PVC, plastic, or any
combination thereof
Piping system 111/211 may be rigid, flexible, or semi-flexible. According to
some
embodiments, piping system 111/211 may be at least partially insulated. A
liquid (e.g.,
blanching solution 106/206) may travel through piping system 111/211 (e.g.,
from source
110/210 to applicator 114/214) under the influence of any force (e.g.,
gravity, pumping,
forced air) or combination of forces. Piping system 111/211 may be a single
element or a
series of elements without deviating from the scope of this disclosure.
Moreover, the scope
of the present disclosure includes the possibility that additional elements
(e.g., gauges,
pumps) may be interspersed along piping system 111/211.
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According to some embodiments, applicator 114/214 may comprise any element or
combination of elements that is operable to permit blanching solution 106/206
to exit
applicator 114/214 (e.g., in a controlled flow) and contact a blanching tray
117/217 and/or a
biomass 104/204. For example, applicator 114/214, in some embodiments, may be
a shower.
In some embodiments, applicator 114/214 may be operable to release a blanching
solution as
a cascade, a shower, a spray, a mist, a fog, a pour, a drip, or any
combination thereof In
some embodiments, applicator 114/214 may comprise a body having an input and
at least one
hole. An input, according to some embodiments may be operable to accept an
input source
(e.g., piping system 111/211) where the input source is capable of
transporting a liquid (e.g.,
blanching solution 106/206). Applicator 114/214 may be operable in some
embodiments, to
direct a stream of liquid (e.g., blanching solution) from the input to the at
least one hole such
that at least some of the liquid exits the applicator through the at least one
hole. An at least
one hole may be of any size and/or shape. In some embodiments an at least one
hole may be
a perforated screen, a porous material (e.g., polyester filter cloth), or any
combination
thereof According to some embodiments, applicator 114/214 may be configured to
cascade
blanching solution in a selected droplet size and/or volume (e.g., a stream
size) through at
least one hole. For example, in some embodiments, a applicator 114/214 may be
configured
to cascade blanching solution 106/206 in droplet or stream sizes of about 5
uL, or about 10
uL, or about 20 uL, or about 30 IA, or about 40 uL, or about 50 IA, or about
100 uL, or
about 200 L. According to some embodiments, applicator 114/214 may be
configured such
that blanching solution 106/206 cascades at a droplet size and rate such that
a stream of
blanching solution exits applicator 114/214. In some embodiments, applicator
114/214 may
comprise a body comprising a box, an input connected to a top side of the box
and accepting
an input source, and at least one hole on the bottom side of the box. In some
embodiments,
the at least one hole may be 3/16 in (about 0.5 cm) in size. According to some
embodiments,
a hole may be by a layer of porous material, for example a polyester filter
cloth (e.g., 3/16 in
(about 0.5 cm) thick).
In some embodiments, applicator 114/214 may be operable to cascade blanching
solution 106/206 in a controlled flow, such that a selected volume of
blanching solution is
cascaded over a selected period of time. For example, applicator 114/214 may
be operable to
cascade blanching solution 106/206 at a rate of at least 0.5 L/min, or at
least 1 L/min, or at
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least 2 L/min, or at least 3 L/min, or at least 4 L/min, or at least 5 L/min,
or at least 6 L/min,
or at least 7 L/min, or at least 8 L/min, or at least 10 L/min, or at least
about 25 L/min, or at
least about 50 L/min, or at least about 100 L/min, or at least about 200
L/min, or at least
about 300 L/min, or at least about 500 L/min, or at least about 750 L/min, or
at least about
1000 L/min, or at least about 1500 L/min, or at least about 2000 L/min, or at
least about 2250
L/min, or at least about 2500 L/min, in some embodiments.
An apparatus for blanching (e.g., continuously blanching) a microcrop 100/200,
in
some embodiments, may further include a heating element 112/212 operable to
heat
blanching solution 106/206, a separated solution (e.g., FIGURE 2 235, a
dilution solution
(e.g. FIGURE 2 208), or any combination thereof A heating element 112/212 may
be placed
in various locations throughout apparatus 100/200 without departing from the
scope of the
instant disclosure. For example, in some embodiments, a heating element, may
be directly or
indirectly connected to source 110/210, or piping system 111/211, or
applicator 114/214, or a
collection tank 136/236, or a dilution source 142/242, or any combination
thereof A
blanching solution 106/206, a separated solution (e.g., FIGURE 2 235, a
dilution solution
(e.g. FIGURE 2 208), or any combination thereof may enter, bypass, or
otherwise interact
with heating element 112/212 to form a heated blanching solution, according to
some
embodiments. As shown in FIGURE 1, in some embodiments, heating element 112
may be
incorporated within or adjacent to source 110 (e.g., heating element
incorporated within a
holding tank) such that blanching solution 106 may be heated at or adjacent to
source 110.
According to some embodiments, heating element 112/212 may be incorporated in
or
adjacent to one or more points along piping system 111/211 such that blanching
solution
106/206 may be heated while traveling from source 110/210 to applicator
114/214. As
shown in FIGURE 2, in some embodiments, heating element 112/212 may be
incorporated in
or adjacent to applicator 114/214 such that blanching solution 106/206 may be
heated after
traveling through pipe 111/211. In some embodiments, apparatus 100/200 may
have multiple
heating elements, with a location of each heating element selected
independently. For
example, in some embodiments, apparatus 100/200 may have a first heating
element
incorporated in or adjacent to applicator 114/214 and a second heating element
incorporated
in or adjacent to a dilution source 142/242.
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Heating element 112/212 may be operable to heat blanching solution 106/206 to
a
temperature of at least 60 C, or at least 65 C, or at least 70 C, or at
least 75 C, or at least
80 C, or at least 85 C, or at least 90 C, or at least 95 C, or at least
100 C, according to
some embodiments.
According to some embodiments, blanching tray 117/217 may be oriented to
receive a
volume of blanching solution 106/206 exiting applicator 114/214 (e.g., through
at least one
hole). Blanching tray 117/217 may be operable to contain biomass 104/204
(e.g., first
portion, second portion) and/or a volume of blanching solution 106/206.
Blanching tray
117/217 may have any dimensions and composition suitable for its operability.
According to
some embodiments, a blanching tray 117/217 may be square or rectangular in
shape. In some
embodiments, blanching tray 117/217 may have a first side 118/218 opposite a
second side
119/219 and a third side opposite a fourth, where the first side, third side,
and fourth side
each have a first height and the second side has a second height which is less
than the first
height. For example, in some embodiments, a second side may be a weir operable
to
maintain a desired volume of a blanching solution in a blanching tray.
According to some
embodiments, a top edge of a second side may include one or more notches. A
blanching
tray 117/217, in some embodiments, may have a depth of about 0.5 cm, or about
1 cm, or
about 2 cm, or about 3 cm, or about 4 cm, or about 5 cm, or about 6 cm, or
about 8 cm, or
about 10 cm, where "about" may be, for example, plus or minus 1 cm. According
to some
embodiments, a second side of a blanching tray may have a height about 0.5 cm
less than a
height of a first side of the blanching tray, or about 1 cm less, or about 2
cm less, or about 3
cm less, or about 4 cm less, or about 5 cm less than a height of a first side,
a third side, and a
fourth side of the blanching tray, where "about" may be, for example, plus or
minus 0.5 cm..
According to some embodiments, blanching tray 117/217 may be transiently
(e.g.,
placed on a surface of) or fixedly attached to a transport system such as a
conveyor belt. In
some embodiments, such a transport system may be used to drive blanching tray
117/217 in a
direction such that cascading blanching solution 106/206 from applicator
114/214 enters
blanching tray 117/217. In other embodiments, blanching tray 117/217 may be
stationary
and applicator 114/214 may be positioned such that at least a portion of a
cascade of
blanching solution 106/206 exiting applicator 114/214 enters blanching tray
117/217.
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As shown in FIGURES 1 and 2, apparatus 100/200 may include a vibratory
mechanism 120/220 capable of vibrating blanching tray 117/217 to generate a
net motion
(e.g., a wave action) of a volume of blanching solution 106/206 within
blanching tray
117/217. In some embodiments, vibratory mechanism 120/220 may be directly
connected to
or incorporated into a design of blanching tray 117/217. In other embodiments,
vibratory
mechanism 120/220 may be adjacent to blanching tray 117/217. For example,
vibratory
mechanism 120/220 may include a platform suspended on a system of springs
121/221 such
that blanching tray 117/217 may be attached (e.g., fixedly, removably) to the
platform and
thereby exposed to vibrational forces (e.g., oscillation) generated. A
vibratory mechanism
120/220, in some embodiments, may be installed directly on a platform being
vibrated or
indirectly coupled to the platform being vibrated. In some embodiments, a
vibratory
mechanism 120/220 may comprise one or more one-axis motors, one or more
stepper motors,
one or more servo motors, one or more axis motor drives, one or more weights
(e.g.,
balanced, unbalanced), or any combination thereof
According to some embodiments, vibratory mechanism 120/220 may generate a net
motion of a volume of blanching solution 106/206. A net motion of a volume of
blanching
solution 106/206, in some embodiments, may generate a motive force capable of
directing
(e.g., propelling) biomass 104/204 from a first side of blanching tray 117/217
to a second side
of blanching tray, where the first side is opposite the second side. In some
embodiments, a
second side of a blanching tray may have a height less than a height of a
first side of the
blanching tray (e.g., a weir); thereby allowing a volume of blanching solution
and/or a mass
of biomass to exit the blanching tray after it is transported from the first
side 118/218 to the
second side 119/219 of the blanching tray.
In some embodiments, a net motion of a volume of blanching solution 106/206
may
include a disturbance on a top surface of the volume of blanching solution
(e.g., a wave
action, a ridge, a swell, a wave-like action) . A disturbance on a top surface
of the volume of
blanching solution (e.g., a wave action, a ridge, a swell) may be capable of
depositing any
quantity of blanching solution onto a top surface (i.e., a surface facing away
from a bottom
surface of blanching tray 117/217) of biomass 104/204. A net motion (e.g.,
wave action) of a
volume of blanching solution 106/206 may result in a top surface (i.e., a
surface facing away
from a bottom surface of blanching tray 117/217) of biomass 104/204 to be
covered by a
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quantity of blanching solution 106/206 (e.g., repeatedly covered, partially
covered). For
example, a net motion of a volume of blanching solution 106/206 (e.g., having
a wave action)
may result in a top surface of biomass 104/204 being repeatedly exposed to the
volume of
blanching solution as a disturbance of the blanching solution (e.g., one or
more waves)
rolling across blanching tray 117/217. According to some embodiments, a mass
of biomass
104/204 and/or a volume of blanching solution 106/206 may exit blanching tray
117/217
after being propelled from a first side of blanching tray 118/218 to a second
side of blanching
tray. Exposure of a biomass 104/204 to a net motion (e.g., disturbance through
wave action)
of a volume of blanching solution 106/206 may result in more uniform blanching
of the
biomass.
According to some embodiments, an apparatus for blanching (e.g., continuously
blanching) a microcrop 100/200 may include a first gauge 122/222. In some
embodiments, a
first gauge 122/222 may be incorporated into, or attached (e.g., removably,
fixedly), or
adjacent to blanching tray 118/218. In some embodiments, a first gauge 122/222
may be
operable to measure one or more of the following: a volume of blanching
solution 106/206
within blanching tray 118/218; a mass of biomass 104/204 within blanching
tray; a volume of
blanching solution exiting blanching tray; a mass of biomass exiting blanching
tray; a
temperature of blanching solution within blanching tray (e.g., average
temperature, at specific
locations); a temperature of blanching solution exiting blanching tray; a rate
of net motion; a
height and frequency of a displacement of a volume of blanching solution
(e.g., wave action);
a displacement of a blanching tray (e.g., relative to a set point on a
platform); a dissolved
solids content (e.g., ash) of blanching solution. In some embodiments, first
gauge 122/222
may be capable of communicating with (e.g., directly; through a central
control system)
heating element 112/212, applicator 114/214, vibratory mechanism 120/220, a
tank 136/236,
a pump and valve system 148/248, or any combination thereof such that various
conditions
may be adjusted including: a rate of blanching solution cascading from
applicator 114/214, a
temperature of blanching solution 106/206 exiting applicator, a rate of net
motion, a dilution
rate (i.e., rate of diluting a separated solution), or any combination thereof
According to
some embodiments, a first gauge 122/222 may communicate with (e.g., directly,
through a
central control system) with one or more components of apparatus 100/200 to
maintain or
adjust a desired product flow rate ratio (e.g., 7:1) or a dilution rate (e.g.,
2.5:1).
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As shown in FIGURE 1, according to some embodiments, after being propelled
from
a first side of blanching tray 118 to a second side of blanching tray 119,
where the first side is
opposite the second side, a mass of biomass 104 and/or a volume of blanching
solution 106
may exit the blanching tray (e.g., via a weir) and enter a dewatering
mechanism 134. A
dewatering mechanism, in some embodiments, may be operable to separate
blanching
solution 106 from a blanched biomass 146. A blanching solution 106 may be
separated from
a blanched biomass 146, in some embodiments, using gravity separation,
draining, an
inclined screen, a vibratory screen, filtration, a decanter centrifuge, a belt
press, a fan press, a
rotary press, a screw press, a filter press, a finisher press, or any
combination thereof
As shown in FIGURE 2, according to some embodiments, after being propelled
from
a first side of blanching tray 118 to a second side of blanching tray 119,
where the first side is
opposite the second side, a mass of biomass 204 and/or a volume of blanching
solution 206
may exit the blanching tray(e.g., via a weir) and enter a settling tank 224. A
settling tank 224
may be, directly or indirectly, connected to blanching tray 218 in such a way
that a mass of
biomass 204 and a volume of blanching solution 206 may flow into settling tank
224 (e.g.,
gravity flow, propulsion). According to some embodiments, a settling tank 224
may be,
oriented relative to blanching tray 218 in such a way that a mass of biomass
204 (e.g., first
portion, second portion) and a volume of blanching solution 206 may flow into
settling tank
224 (e.g., gravity flow, propulsion). Settling tank 224 may be operable to
allow contaminants
and/or debris to become dislodged from a mass of biomass 204 and sink below a
surface of a
settling solution. In some embodiments, a settling tank 224 may be operable to
remove non-
buoyant solids from biomass 204. Non-buoyant solids, in some embodiments, may
include
fresh water arthropods or mollusks (e.g., gammarus and snails). Blanching
unwanted
lifeforms, in some embodiments, may result in a buoyancy change of those
lifeforms such
that previously buoyant lifeforms become non-buoyant.
Settling tank 224 may have any dimensions and composition suitable for its
operability. According to some embodiments, a settling tank may be square or
rectangular in
shape (e.g., when viewed from above). In some embodiments, settling tank 224
may have a
first side 225 opposite a second side 226 and a third side opposite a fourth,
where the first
side, third side, and fourth side each have a first height and the second side
226 has a second
height which is less than the first height. For example, in some embodiments,
a second side
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226 may be a weir operable to maintain a desired volume of a blanching
solution in a
blanching tray. According to some embodiments, a top edge of a second side may
include
one or more notches. A settling tank 224, in some embodiments, may have a
depth of about
cm, or about 7.5 cm, or about 10 cm, or about 12.5 cm, or about 15 cm, or
about 17.5 cm,
5 or about 20 cm, or about 22.5 cm, or about 25 cm, or about 30 cm, or
about 35 cm, or about
40 cm, or about 45 cm, or about 50 cm, where "about" may represent, for
example, plus or
minus 2 cm.
In some embodiments, settling tank 224 may contain a volume of a settling
solution.
A settling solution may include any liquid having characteristics which permit
contaminants
and/or debris to sink away from a top surface of the settling solution.
According to some
embodiments, a settling solution may comprise a blanching solution 206. A
settling solution,
in some embodiments, may comprise water, ground water, well water, distilled
water,
deionized water, reverse osmosis water, nanofiltered water, ultra-filtered
water, or any
combination thereof In some embodiments, a settling solution may be selected
to have a
specific viscosity.
In some embodiments, settling tank 224 may include one or more sloping sides
and/or
a sloping bottom which may aid in removal of contaminants, debris, or non-
buoyant solids
that sink below a surface of a settling solution. Settling tank 224, in some
embodiments, may
include filters or screens that may aid in separating a biomass from debris,
contaminants,
and/or non-buoyant solids. For example, in some embodiments, a settling tank
may include a
screen across a surface of the settling tank but below a top surface of a
settling solution. A
screen, in some embodiments, may include a mesh size small enough to retain a
biomass but
large enough to allow at least some debris, contaminants, and/or non-buoyant
solids to pass
through. In some embodiments, a screen may be capable of vibratory motion such
that a
biomass may be transported from a first side 225 of a settling tank to a
second side 226 of the
settling tank, where the first side and the second side are opposite.
According to some
embodiments, a mass of debris, contaminant, and/or non-buoyant solids may be
expelled
from a settling tank 224 (e.g., from a bottom of the settling tank) along with
a volume of
settling solution. A filter 228 may collect the debris, contaminants, and/or
non-buoyant
solids and a stream of settling solution may be collected (e.g., as a
separated solution 235) in
a collection tank 236, in some embodiments.
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According to some embodiments, debris, contaminants, and/or non-buoyant solids
may settle to a bottom of a settling tank. Debris, contaminant, and/or non-
buoyant solids may
be recycled (e.g., used in a microcrop cultivation system, fish food), in some
embodiments.
In some embodiments, settling tank 224 may comprise a propulsion mechanism
operable to convey a biomass (e.g., first portion, second portion) from a
first side of settling
tank 225 to a second side of settling tank 226, where the first side and the
second side are
opposite one another. In some embodiments, a propulsion mechanism may include
gravity,
paddle wheels, bubbling, submerged or surface water jets, submerged mixers, a
vibratory
mechanism, or any combination thereof In some embodiments, a propulsion
mechanism
may include a pump operable to pump a settling solution from an entry point to
an exit point
of settling tank.
According to some embodiments, settling tank 224 may be operable to cool a
biomass. For example, a settling solution within settling tank 224 may have a
temperature
less than a temperature of a blanching solution 206 (e.g., below about 60 C)
or less than an
ambient temperature (e.g., about 23 C). In some embodiments, a settling
solution may have
a temperature below about 90 C, or below about 80 C, or below about 70 C,
or below
about 60 C, or below about 50 C, or below about 40 C, or below about 30 C,
or below
about 20 C at the time of use. A settling solution, in some embodiments, may
have a
temperature between about 20 C and about 80 C, or between about 40 C and
about 80 C,
or between about 40 C and about 60 C, or between about 20 C and about 40
C, or
between about 20 C and about 30 C. at the time of use.
In some embodiments, an apparatus for blanching (e.g., continuously) a
microcrop
200, may include a second gauge 229. In some embodiments, a second gauge 229
may be
incorporated into, or attached (e.g., removably, fixedly), or adjacent to
settling tank 224.
In some embodiments, a second gauge 229 may be operable to monitor, maintain,
and/or adjust a desired product flow rate ratio (e.g., 7:1). A second gauge
229, in some
embodiments, may be operable to measure one or more of the following: a volume
of settling
solution within a settling tank 224; a mass of biomass 204 within settling
tank; a volume of
settling solution exiting settling tank; a mass of biomass exiting settling
tank; a temperature
of settling solution within settling tank (e.g., average temperature, at
specific locations); a
temperature of settling solution exiting settling tank; a dissolved solids
content (e.g., ash) of
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settling solution. In some embodiments, second gauge 229 may be capable of
communicating with (e.g., directly; through a central control system) heating
element
112/212, applicator 114/214, vibratory mechanism 120/220, a tank 136/236, a
pump and
valve system, or any combination thereof such that various conditions may be
adjusted.
According to some embodiments, a second gauge 229 may communicate with (e.g.,
directly,
through a central control system) with one or more components of apparatus
100/200 to
maintain or adjust a desired product flow rate ratio (e.g., 7:1) or a dilution
rate (e.g., 2:1).
As shown in FIGURE 2, after being propelled from a first side 225 of settling
tank to
a second side 226 of settling tank, where the first side is opposite the
second side, a mass of
biomass 204 and/or a volume of settling solution may exit the settling tank
and enter a
dewatering mechanism 234. As shown in FIGURE 1, in some embodiments, after
being
propelled from a first side 118 of blanching tray to a second side 119 of
blanching tray, where
the first side is opposite the second side, a mass of biomass 204 and/or a
volume of blanching
solution 106 may exit the blanching tray and enter a dewatering mechanism 234.
Moreover,
in some embodiments, a biomass 204 may be directly deposited into a dewatering
mechanism
234 without traveling from a first side to a second side of a blanching tray
or a settling tank.
For example, in some embodiments, a blanching tray containing a biomass and a
blanching
solution may be directly emptied (e.g., chute feed, gravity feed) into a
dewatering mechanism
without departing from the scope of the instant disclosure. A dewatering
mechanism, in
some embodiments, may be operable to separate blanching solution 106, a
settling solution, a
rinsing solution, or any combination thereof (individually and collectively "a
separated
solution" 135/235) from a blanched biomass 146. A dewatering mechanism 234, in
some
embodiments, may include using gravity separation, draining, an inclined
screen, a vibratory
screen, filtration, a decanter centrifuge, a belt press, a fan press, a rotary
press, a screw press,
a filter press, a finisher press, or any combination thereof
As shown in FIGURES 1 and 2, in some embodiments, a separated solution 135/235
may be collected and reused/recycled. According to some embodiments, as shown
in
FIGURES 1 and 2, a separated solution 135/235 may be transported (e.g.,
gravity, pumping)
to a collection tank 136/236. A collection tank 136/236 may have any size,
shape,
dimensions, or composition suitable for collecting and retaining liquid. A
separated solution
135/235 within a collection tank 236 may be stationary or moving (e.g.,
agitation,
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propulsion). In some embodiments, an apparatus 100/200 may have a single tank
that may be
operable to function as both a source 110/210 and a collection tank 136/236.
As shown in FIGURES 1 and 2, an apparatus for blanching a microcrop 100/200
may
include a collection tank gauge 138/238. In some embodiments, a collection
tank gauge
138/238 may be operable to monitor, maintain, and/or adjust a desired product
flow rate ratio
(e.g., 7:1). A collection tank gauge 138/238 may be operable, in some
embodiments, to
monitor a composition (e.g., total dissolved solids) and/or temperature of a
separated
solution. Monitoring a composition of a separated solution may include
monitoring one or
more of the following: total dissolved solids, total solids, turbidity,
electrical conductivity,
nutrient (e.g., nitrogen) composition, salinity, pH. A collection tank gauge
238, in some
embodiments, may communicate (e.g., directly, indirectly) with a pump and
valve system
248 in order to regulate a composition of a separated solution (e.g., by
adjusting a dilution
rate).
In some embodiments, collection tank gauge 138/238 may be capable of
communicating with (e.g., directly; through a central control system) with one
or more
components of apparatus 100/200 (e.g., a pump and valve system, a dilution
tank) to maintain
or adjust a total dissolved solids content of a volume of separated solution
135/235 stored in
tank 136/236. For example, a collection tank gauge 138/238, in some
embodiments, may
communicate with one or more components of apparatus 100/200 to maintain or
adjust a total
solids content of a volume of separated solution 135/235 and/or a volume of a
blanching
solution 106/206 at a value of less than 0.5% (w/w), or less than 1% (w/w) or
less than 2%
(w/w), or less than 4% (w/w), or less than 6% (w/w) or less than 8% (w/w), or
less than 10%
(w/w). According to some embodiments, a collection tank gauge 138/238, in some
embodiments, may communicate with one or more components of apparatus 100/200
to
maintain or adjust a turbidity value (e.g., relative to absorbance of a 500 nm
light source
where 1.0 is equivalent to 10% absorbance and 10.0 is equivalent to 100%
absorbance) of a
volume of separated solution 135/235 and/or a volume of a blanching solution
106/206 at a
value of less than about 0.5, or less than about 0.75, or less than about 1.0,
or less than about
1.25, or less than about 1.5, where about may represent plus or minus 5%. In
some
embodiments, a collection tank gauge 138/238, in some embodiments, may
communicate
with one or more components of apparatus 100/200 to maintain or adjust an
electrical
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conductivity value of the separated solution at/to a value of less than about
2000 [tS/cm, or
less than about 2500 [tS/cm, or less than about 3000 [tS/cm, or less than
about 3500 [tS/cm,
or less than about 4000 [tS/cm, or less than about 4500 [tS/cm, or less than
about 5000
[tS/cm, or less than about 5500 [tS/cm, or less than about 6000 [tS/cm, where
"about" may
represent plus or minus 250 [tS/cm. According to some embodiments, a
collection gauge
138/238 may communicate with (e.g., directly, through a central control
system) with one or
more components of apparatus 100/200 to maintain or adjust a desired product
flow rate ratio
(e.g., 7:1).
According to some embodiments, an apparatus 100/200 may include a filter
operable
to filter a separated solution. A filter may be operable, according to some
embodiments, to
achieve coarse filtration (e.g., gravity filtration, vibratory screen
filtration), fine filtration
(e.g., microfiltration, ultrafiltration, nanofiltration, reverse osmosis
filtration), or any
combination thereof A filtered separated solution may be recycled as a wash
solution, as a
growth medium in the cultivation of a microcrop, as a blanching solution, as a
settling
solution, as a rinsing solution, or any combination thereof In some
embodiments, a
blanching waste (e.g., retentate from a filtration method) may be recycled as
part of a growth
medium (e.g., as a nutrient source) in a cultivation of a microcrop.
In some embodiments, a separated solution 135/235 may be diluted prior to
recycling
(e.g., recycling as a blanching solution). Dilution of a separated solution
135/235 may be
desirable to adjust a composition of the separated solution (e.g., dissolved
solids content,
turbidity). A diluted separated solution may be recycled as a blanching
solution 106/206, as a
wash solution (e.g., FIGURE 4 457) as a settling solution, as a rinsing
solution, or any
combination thereof, in some embodiments. In some embodiments, a discard
solution
143/243 may be recycled as a growth medium in the cultivation of a microcrop
(e.g.,
FIGURE 4 450).
As shown in FIGURES 1 and 2, an apparatus for blanching a microcrop may
include
a dilution source 142/242 operable to store and release a dilution solution
108/208, in some
embodiments. A dilution solution 108/208, according to some embodiments, may
include
water, ground water, well water, distilled water, deionized water, reverse
osmosis water,
nanofiltered water, ultra-filtered water, or any combination thereof A
dilution source
142/242, in some embodiments, may include a holding tank, a well, a water
line, or any other
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container or system capable of holding a liquid. In some embodiments, diluting
a separated
solution may include discarding a volume of separated solution (i.e., a
discard solution
143/243) from a collection tank. A discard solution 143/243 may have a volume
equal to a
volume of dilution solution necessary to achieve a desired composition of
dissolved solids
(e.g., ash), according to some embodiments. In some embodiments, a discard
solution
143/243 may have a volume higher than a volume of dilution solution necessary
to achieve a
desired composition of dissolved solids (e.g., ash). A rate of discarding a
volume of
separated solution from a collection tank may be regulated by a collection
tank gauge (e.g.,
total tank volume)
According to some embodiments, a separated solution 135/235 and/or a blanching
solution 106/206 in tank 136/236 may be diluted to comprise a desired
composition of
dissolved solids (e.g., ash) and/or total solids. In some embodiments, a
volume of separated
solution 135/235 and/or a volume of a blanching solution 106/206 in tank
136/236 may be
diluted to have a total solids content at a value of less than 0.5% (w/w), or
less than 1% (w/w)
or less than 2% (w/w), or less than 4% (w/w), or less than 6% (w/w) or less
than 8% (w/w),
or less than 10% (w/w). According to some embodiments, a separated solution
135/235 in
tank 136/236 may be diluted to have a turbidity value (e.g., relative to
absorbance of a 500
nm light source where 1.0 is equivalent to 10% absorbance and 10.0 is
equivalent to 100%
absorbance) of a volume of separated solution 135/235 and/or a volume of a
blanching
solution 106/206 at a value of less than about 0.5, or less than about 0.75,
or less than about
1.0, or less than about 1.25, or less than about 1.5, where about may
represent plus or minus
5%. In some embodiments, a separated solution 135/235 and/or a blanching
solution 106/206
in tank 136/236 may be diluted to have an electrical conductivity value of
less than about
2000 S/cm, or less than about 2500 0/cm, or less than about 3000 0/cm, or
less than
about 3500 0/cm, or less than about 4000 0/cm, or less than about 4500 0/cm,
or less
than about 5000 0/cm, or less than about 5500 0/cm, or less than about 6000
0/cm, where
"about" may represent plus or minus 250 S/cm.
In some embodiments, a separated solution 135/235 in tank 136/236 may be
diluted
relative to a biomass feed rate. For example, an apparatus 100/200 with a feed
rate of 4
kg/min may have a dilution rate of a separated solution 135/235 in tank
136/236 of 8 L/min
resulting in a dilution to feed ratio of 2:1. According to some embodiments,
an apparatus
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100/200 may have a feed to dilution ratio of about 4:1, or about 3.5:1, or
about 3:1, or about
2.5:1, or about 2:1õ or about 1.5:1, or about 1:1, according to some
embodiments.
As shown in FIGURES 1 and 2, in some embodiments, an apparatus for blanching
(e.g., continuously) a microcrop 100/200 may include a pump and valve
mechanism 148/248.
According to some embodiments, a pump and valve mechanism 148/248 may be
operable to
propel one or more of a blanching solution, a settling solution, a rinsing
solution, a separated
solution, and a dilution solution within apparatus 100/200. In some
embodiments, a pump
and valve mechanism 148/248 may communicate with a first gauge, a second
gauge, a
collection tank gauge 138/238, or any combination thereof According to some
embodiments, a pump and valve mechanism 148/248 may communicate with (e.g.,
directly,
through a central control system) with one or more components of apparatus
100/200 to
maintain or adjust a desired product flow rate ratio (e.g., 7:1).
As shown in FIGURES 1 and 2, apparatus 100/200 may include a heat exchanger
144/244. According to some embodiments, a heat exchanger 144/244 (e.g.,
thermal energy
exchange mechanisms) may decrease an overall energy input required for
production of high-
concentration protein product (e.g., protein flake) from a microcrop (e.g.,
Lemna,
According to some embodiments, a heat exchanger 144/244 may include a flow
system
wherein a stream of discard solution 143/243 from collection tank 136/236
(i.e., a donor
stream) and a dilution solution stream (i.e., recipient stream) are adjacent
such that thermal
energy exchange may occur. In some embodiments, a dilution solution stream
(i.e., a
recipient stream) may have a cooler temperature and thereby a lower thermal
energy than a
donor stream (e.g., a discard solution stream 143/243 which retains heat from
a blanching
solution). According to some embodiments, a heat exchanger may include a flow
system
(e.g., a series of pipes composed of convective material) such that a dilution
solution stream
(i.e., a recipient stream) may absorb at least some thermal energy from a
discard solution
stream 143/243 (i.e., a donor stream). In some embodiments, a heat exchanger
144/244 may
result in increasing a temperature of a dilution solution stream and/or a
diluted separated
solution in tank 136/236. In some embodiments, a heat exchanger 144/ 244 may
reduce an
amount of energy required for heating a recycled solution in heating element
212.
As shown in FIGURE 2, according to some embodiments, after being separated
from
a blanching solution 206 and/or a settling solution, a blanched biomass 246
may be conveyed
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to a rinsing mechanism 230. A rinsing mechanism 230 may be, directly or
indirectly,
connected to dewatering mechanism 234 in such a way that a blanched biomass
246 may be
conveyed into rinsing mechanism 230 by gravity or propulsion.
In some embodiments, a rinsing mechanism 230 may be operable to remove
unwanted dissolved solids from a blanched biomass 246. Rinsing mechanism 230
may have
any dimensions and composition suitable for its operability. In some
embodiments, a rinsing
mechanism may include a sprinkler and a vibratory screen. According to some
embodiments,
a rinsing mechanism may include a rinsing tank having any suitable dimensions
of shape. A
rinsing tank 230, in some embodiments, may have a depth of at least about 5 cm
in, or at least
about 10 cm, or at least about 15 cm, or at least about 20 cm, or at least
about 25 cm where
"about" may be, for example, plus or minus 3 cm. In some embodiments, a
rinsing
mechanism 230 may be capable of containing a blanched biomass 246 and/or a
volume of a
rinsing solution. According to some embodiments, a rinsing mechanism 230
(e.g., rinsing
tank) may be operable to receive a rinsing solution such that the rinsing
solution contacts at
least one surface of a blanched biomass 246 within the rinsing mechanism. In
some
embodiments, a rinsing mechanism 230 (e.g., rinsing tank) may contain a volume
of a rinsing
solution such that a blanched biomass 246 floats on a surface of the rinsing
solution. In other
embodiments, a rinsing mechanism may include a sprinkler mechanism such that a
volume of
rinsing solution is deposited on at least one surface of a blanched biomass
246. A rinsing
mechanism, in some embodiments, may further comprise a vibratory screen such
that at least
some of a rinsing solution may be removed from a blanched biomass.
According to some embodiments, a rinsing solution may include water, distilled
water, reverse osmosis water, nanofiltered water, a blanching solution 206, a
settling solution,
a recycled blanching solution, a recycled settling solution, a recycled
rinsing liquid, or any
combination thereof According to some embodiments, a rinsing solution may be
sterilized
(e.g., UV radiation, filtration, heating).
Rinsing mechanism 230, in some embodiments, may be operable to cool a blanched
biomass 246. For example, a rinsing solution within rinsing tank 230 may have
a
temperature less than a temperature of a blanching solution 206, or less than
an ambient
temperature. In some embodiments, a rinsing solution may have a temperature
below room
temperature (e.g., about 12 C) at the time of use. In some embodiments, a
rinsing solution
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may have a temperature below about 50 C, or below about 40 C, or below about
30 C, or
below about 20 C, or below about 15 C, or below about 10 C, or below about
5 C, or
below about 2 C, or below about 1 C, or below about 0 C at the time of use.
In some embodiments, rinsing mechanism 230 may comprise a propulsion mechanism
operable to convey a blanched biomass from a first side of the rinsing
mechanism to a second
side of the rinsing mechanism, where the first side and the second side are
opposite one
another. For example, in some embodiments, a rinsing mechanism may include a
propulsion
system and a rinsing tank where the propulsion mechanism propels a blanched
biomass from
a first side of the rinsing tank to a second side of the rinsing tank. In
other embodiments, a
rinsing mechanism 230 may include a vibratory screen and a sprinkler system,
where the
vibratory screen propels the blanched biomass from a first side to a second
side. According
to some embodiments a propulsion mechanism of a rinsing mechanism may include
gravity,
paddle wheels, bubbling, submerged or surface water jets, submerged mixers, a
vibratory
mechanism, or any combination thereof
As shown in FIGURES 1 and 2, in some embodiments, a rinsing mechanism 230 may
include components capable of separating a volume of rinsing solution from a
blanched
biomass (e.g., vibratory screen) to generate a separated solution 235.
According to some
embodiments, a separated solution may be collected in a collection tank 236,
diluted, filtered,
recycled, or any combination thereof
METHODS FOR GENERATING A HIGH-CONCENTRATION PROTEIN PRODUCT BY
BLANCHING OF A MICROCROP
Cultivation of a Microcrop
In some embodiments a microcrop may be asexually propagated (e.g., cultivated)
by
contacting the microcrop with a first medium (e.g., an aqueous nutrient
composition, a
growth medium) under conditions that permit expansion. A microcrop may be
cultivated
(e.g., FIGURE 3 350, FIGURE 4 450) in a bioreactor system, according to some
embodiments. A bioreactor system may contain a first medium (e.g., a growth
medium)
comprising water and/or a nutrient composition, according to some embodiments.
A nutrient
composition, in some embodiments, may include at least one of nitrogen,
phosphorus,
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potassium, and calcium. In some embodiments, a first medium may comprise
dissolved
gaseous oxygen and/or dissolved gaseous carbon dioxide. According to some
embodiments,
a first medium may be configured to have an increased calcium composition
(e.g., an
increased calcium growth medium). For example, an increased calcium first
medium may
comprise a calcium concentration of > about 120 parts per million (ppm), or >
about 115
ppm, or > about 110 ppm, or > about 105 ppm, or > about 100 ppm, or > about 95
ppm, or >
about 90 ppm, or > about 85 ppm, or > about 80 ppm, or > about 75 ppm, or >
about 70 ppm,
or > about 65 ppm, or > about 60 ppm, or > about 55 ppm, or > about 50 ppm, or
> about 45
ppm, or > about 40 ppm, or > about 35 ppm, or > about 30 ppm, or > about 25
ppm, or >
about 20 ppm, where "about" constitutes plus or minus 10%. In some
embodiments, an
increased calcium first medium may comprise a calcium concentration of about
20 ppm to
about 120 ppm, about 25 ppm to about 120 ppm, or about 30 ppm to about 120
ppm, or about
40 ppm to about 120 ppm, or about 50 ppm to about 120 ppm, or about 60 ppm to
about 120
ppm, or about 70 ppm to about 120 ppm, or about 80 ppm to about 120 ppm, or
about 20 ppm
to about 100 ppm, or about 30 ppm to about 100 ppm, or about 40 ppm to about
100 ppm, or
about 50 ppm to about 100 ppm, or about 60 ppm to about 100 ppm, or about 70
ppm to
about 100 ppm, or about 80 ppm to about 100 ppm. An increased calcium first
medium,
according to some embodiments, may comprise a calcium concentration of at
least about 20
ppm (e.g., 10%). In some embodiments an increased calcium first medium
comprises at
least 100 ppm calcium. A bioreactor system may be configured to insert
additional nutrients
(e.g., nitrogen, phosphorus, potassium, calcium) or gases (e.g., oxygen;
carbon dioxide) into
the first medium at specified time indicators or in response to sensor
readings. In some
embodiments, a calcium may comprise calcium, calcium carbonate, calcium
oxalate, calcium
oxide, calcium citrate, calcium carbide, calcium phosphate, calcium sulfate,
calcium chloride,
or combinations thereof
In some embodiments, a first medium may comprise one or more anti-
photosynthetic
dyes that are configured to attenuate photosynthetically active radiation
within the growth
medium. The one or more anti-photosynthetic dyes may be added at a sufficient
volume or
concentration to inhibit growth of at least one other aquatic organism (e.g.,
submerged
aquatic species, phytoplankton, phytoalgae, epiphytic algae), according to
some
embodiments. An anti-photosynthetic dye may include at least one of (n-ethyl-n-
[4-[[4-
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[ethyl [(3 -sulfopheny Omethyl] amino] - phenyl] (2-sulfopheny1)-methylene)]
2,5-cy cl ohexadi en-
1-ylidene]-3-sulfobenzenemethanaminium hydroxide inner salt, disodium salt,
(Colour Index
Acid Blue 9 (Ref No. 42090)), trisodium (4E)-5-oxo-1-(4-sulfonatopheny1)-4-[(4-
sulfonatophenyphydrazono1-3-pyrazolecarboxylate (Colour Index Acid Yellow 23
(Ref No.
19140)), di azanium; 2- [ [4- [ethyl- [(3 -sulfonatopheny Omethyl] amino]
phenyl] -[4- [ethyl- [(3-
sulfonatophenyl) methyl] azaniumylidene] cy
cl ohexa-2,5 -di en-1 -ylidenel methyl]
benzenesulfonate (Colour Index Acid Blue 34 (Ref No. 42645)); benzy144-[[4-
[benzyl(ethyl)amino] phenyl] -(5 -hy droxy -2,4-di sulfophenyl)methy dene] cy
cl ohexa-2,5 -di en-
1-ylideneFethylazanium (Colour Index Acid Blue 5 (Ref No. 42052)); disodium-2-
(1,3-
dioxoinden-2-yl)quinoline-6,8-disulfonate (Colour Index Acid Yellow 3 (Ref No.
15985)),
and a mixture of (n-ethyl-n-[4-[[4-[ethyl[(3-sulfophenyOmethyl]amino1-
phenyl](2-
sulfopheny1)-methylene)] 2,5-cy cl ohexadi en-1 -y dene] -3 -s ulfob
enzenemethanaminium
hydroxide inner salt, disodium salt and trisodium (4E)-5-oxo-1-(4-
sulfonatopheny1)-4-[(4-
sulfonatophenyphydrazono1-3-pyrazolecarboxylate (Aquashade0).
Other suitable anti-
photosynthetic dyes may be found in Tables I and II of U.S. Patent No.
4,042,367 to Wilson,
which is incorporated herein by reference.
A first medium (e.g., an aqueous nutrient composition) may be provided in
and/or
added to a bioreactor (e.g., a pond) and may be maintained at a desired set-
point level (e.g.,
specific volume), according to some embodiments. A bioreactor system, in some
embodiments, may be configured to collect rainfall and/or to intake water from
a source of
ground, surface, or recycled water (e.g., storm water, recycled water) or any
other suitable
water source. According to some embodiments, a bioreactor system may further
comprise an
additional storage container (e.g., container or pond) for excess growth
medium.
In some embodiments, one or more smaller bioreactors (e.g., pond) may be
designed
and sized to adequately serve as "feeder" bioreactors to a larger bioreactor.
Smaller
bioreactors, in some embodiments, may be first inoculated and grown to high
density at
which point they may optimally seed a larger bioreactor in a manner that
supports faster
growth.
In some embodiments, a bioreactor system may comprise a monitoring system. A
monitoring system may be configured to display and/or provide one or more user
alerts
regarding bioreactor condition(s) (e.g., nutrient concentrations, pH,
dissolved oxygen levels,
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growth medium levels, microcrop distribution, flow rate, temperature) and/or
adjust operating
conditions (e.g., growth medium flow rate and /or timing and/or quantity of
nutrient addition;
"feeder" microcrop addition, oxygen or carbon dioxide addition), in some
embodiments.
Adjustments may be made continuously, semi-continuously, periodically,
intermittently, as
needed, at set or variable times, or any other interval. In some embodiments,
adjustments
may be selected to optimize growth rates and/or yield of the aquatic species.
For example, a
microcrop species may be grown in large-scale, open bioreactors with
monitoring systems
configured to adjust the introduction of materials (e.g., fresh or recycled
water, fresh or
recycled growth media) based on, for example, exposure to light, which may
thereby regulate
nutrient consumption rates.
A bioreactor system may comprise, in some embodiments, a single container in
which
the microcrop may be cultivated. In some embodiments, the bioreactor system
may comprise
multiple cultivation containers that may be connected, partially connected, or
disconnected.
A bioreactor (e.g., a pond), in some embodiments, may be an earthen basin with
the
embankments made of compacted dirt removed from the interior bottom of the
bioreactor.
According to some embodiments the bioreactor may be an artificial container
(e.g., metal,
plastic, resin). A bioreactor system may comprise an open bioreactor, a closed
bioreactor, a
semi-open bioreactor, or any combination thereof In some embodiments, a
bioreactor
system may be configured to divide the container(s) into channels or cells. A
bioreactor
system may be configured to permit a flow of growth medium, in some
embodiments. A
bioreactor system, in some embodiments, may include a propulsion system (e.g.,
paddle
wheels, bubbling, submerged or surface water jets, submerged mixers) and/or a
recirculation
system. In some embodiments, a bioreactor system may be configured to adjust
the flow rate
of a growth medium (e.g., to redistribute nutrient concentrations or microcrop
growth
patterns).
In some embodiments a bioreactor system may be open (e.g., in a horizontal
plane
relative to the ground) of a bioreactor container (e.g., serpentine raceway)
such that a growth
medium contained within the bioreactor container and/or a microcrop growing on
a top
surface of the growth medium may be exposed to a wind initiating from an
exterior of the
bioreactor container. A bioreactor system, according to some embodiments, may
be partially
open (e.g., in a horizontal plane relative to the ground) with at least 90% or
at least 80%, or at
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least 70%, or at least 60%, or at least 50%, or at least 40%, or at least 30%,
or at least 20%, or
at least 10% of the top surface of the contained culture media being open. A
top surface may
be open, according to some embodiments, where the surface is substantially
free (e.g., free)
of any covering or other barrier, where the surface is directly exposed to
ambient weather
conditions, where there is substantially no membrane, glass, cover or other
barrier (whether
or not such barrier has pores or apertures) between the surface and the
atmosphere, and/or
where ambient atmosphere is the only occupant of the space immediately and
directly above
the surface for a distance of at least about 1 meter above the surface.
A bioreactor system, in some embodiments, may monitor and adjust a thickness
and
distribution of a microcrop mat. For example, when a microcrop reaches a
specified
thickness or distribution a bioreactor system may initiate harvest procedures.
In some
embodiments, a minimum thickness of a microcrop mat may be maintained such
that a
desired evapotranspiration rate of a growth medium within a bioreactor system
may be
maintained. A minimum thickness of a microcrop may be maintained, in some
embodiments,
such that less sunlight is capable of penetrating a surface of a growth medium
(i.e., reducing a
growth potential of submerged aquatic species such as algae).
A microcrop may be cultivated by any suitable method and is not limited to the
method described herein. Various changes may be made in the method of
cultivation of a
microcrop without departing from the scope of the instant disclosure.
Harvesting of a Microcrop
As shown in FIGURES 3 and 4, a microcrop may be harvested 351/451 in whole or
in
part at any desired time(s) to form a biomass 352/452. For example, a
microcrop may be
harvested at one or more specific times, at regular or irregular intervals
and/or continuously.
Selection of harvest time(s) and/or intervals may be based on environmental
conditions (e.g.,
precipitation, relative humidity, temperature range, average, low or high
threshold and/or
light intensity, wavelength range, duration of exposure) and/or the microcrop
exhibiting one
or more desired characteristics (e.g., mat thickness, mat distribution,
maturation). Harvesting
a microcrop may be manual or automated. In some embodiments, an automated
skimmer
system may collect a microcrop from a bioreactor system and transfer a
harvested microcrop
(e.g., via a pumping system) onto an inclined vibrating screen to separate a
biomass from
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growth medium and debris. A microcrop, in some embodiments, may be harvested
by
vacuum skimming the microcrop from the bioreactor system through a stationary
or mobile
screen filter. According to some embodiments, a biomass slurry, including a
harvested
microcrop (e.g., Lemna) and a growth medium (e.g., water), may be conveyed to
an inclined
vibrating screen where a biomass (e.g., microcrop) may be separated from the
growth
medium.
As shown in FIGURES 3 and 4, during harvesting, a separated growth medium may
be recycled 353/453 back into the bioreactor system or to an additional
storage container
(e.g., container or pond), according to some embodiments. In some embodiments,
at least
about 40%, or at least about 50%, or at least about 60%, or at least about
70%, or at least
about 80%, or at least about 90%, or at least about 95% of a growth medium
(e.g., water)
separated from a biomass may be recycled for further use in cultivating,
harvesting, and/or
processing a microcrop. In some embodiments, recycling a separated growth
medium may
include filtering a separated growth medium by coarse filtration (e.g.,
gravity filtration,
vibratory screen filtration), fine filtration (e.g., microfiltration,
ultrafiltration, nanofiltration,
reverse osmosis filtration), or any combination thereof
Soaking and/or Buffering a pH of a Biomass
After harvesting, a biomass may be soaked (e.g., FIGURE 4 454) and/or
buffered.
Soaking and/or buffering a harvested biomass may contribute to a reduction in
an oxalic acid
content of a protein product. In some embodiments, soaking and/or buffering a
harvested
biomass may contribute to a reduction in an oxalic acid and/or oxalate content
of a protein
product.
In some embodiments, a harvested biomass may be soaked in a second medium
(e.g.,
FIGURE 4 454). A second medium may comprise water (e.g., ground water, surface
water,
recycled water), distilled water, reverse osmosis or nanofiltered water,
and/or a nutrient
composition, according to some embodiments. In some embodiments, a second
medium may
comprise any desired portion of recycled fluid. For example, a second medium
may
comprise at least about 10% (v/v), at least about 20% (v/v), at least about
30% (v/v), at least
about 40% (v/v), at least about 50% (v/v), at least about 60% (v/v), at least
about 70% (v/v),
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at least about 80% (v/v), or at least about 90% (v/v) recycled fluid from
another stage of the
process.
According to some embodiments, a second medium may be configured to have a low
nitrogen composition (e.g., a low nitrogen second medium). For example, a low
nitrogen
second medium may comprise a nitrogen concentration of < about 20 parts per
million (ppm),
< about 18 ppm, < about 16 ppm, or < about 14 ppm, or < about 12 ppm, or <
about 10 ppm,
or < about 9 ppm, or < about 8 ppm, or < about 7 ppm, or < about 6 ppm, or <
about 5 ppm,
or < about 4 ppm, or < about 3 ppm, or < about 2 ppm, or < about 1 ppm, or <
about 0.5 ppm,
or about 0 ppm. In some embodiments, a low nitrogen second medium may comprise
a
nitrogen concentration of about 0 ppm to about 20 ppm, or about 0.5 ppm to
about 20 ppm, or
about 0.5 ppm to about 15 ppm, or about 0.5 ppm to about 10 ppm, or about 1
ppm to about 9
ppm, or about 1 ppm to about 7 ppm, or about 1 ppm to about 6 ppm, or about 1
ppm to about
5 ppm, or about 3 ppm to about 6 ppm, or about 2 ppm to about 8 ppm. A low
nitrogen
second medium, according to some embodiments, may comprise a nitrogen
concentration of
at most about 10 ppm (e.g., 1 ppm). In some embodiments, a low nitrogen
second medium
may comprise a nitrogen concentration of at most about 5 ppm (e.g., 0.5
ppm). A low
nitrogen second medium may comprise at least some quantity of nitrogen in
contrast to, for
example, a no nitrogen second medium having no detectable nitrogen (i.e., N2).
In some
embodiments, a second medium may be a no nitrogen second medium.
According to some embodiments, a second medium may be configured to have a low
calcium composition (e.g., a low calcium second medium). For example, a low
calcium
second medium may comprise a calcium concentration of < about 20 ppm, < about
18 ppm, <
about 16 ppm, or < about 14 ppm, or < about 12 ppm, or < about 10 ppm, or <
about 9 ppm,
or < about 8 ppm, or < about 7 ppm, or < about 6 ppm, or < about 5 ppm, or <
about 4 ppm,
or < about 3 ppm, or < about 2 ppm, or < about 1 ppm, or < about 0.5 ppm, or
about 0 ppm.
In some embodiments, a low calcium second medium may comprise a calcium
concentration
of about 0 ppm to about 20 ppm, or about 0.5 ppm to about 20 ppm, or about 0.5
ppm to
about 15 ppm, or about 0.5 ppm to about 10 ppm, or about 1 ppm to about 9 ppm,
or about 1
ppm to about 7 ppm, or about 1 ppm to about 6 ppm, or about 1 ppm to about 5
ppm, or about
3 ppm to about 6 ppm, or about 2 ppm to about 8 ppm. A low calcium second
medium,
according to some embodiments, may comprise a calcium concentration of at most
about 10
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ppm (e.g., 1 ppm). In some embodiments, a low calcium second medium may
comprise a
calcium concentration of at most about 5 ppm (e.g., 0.5 ppm). In some
embodiments,
soaking a biomass in a low calcium second medium may effect the equilibrium
between an
oxalic acid concentration and an oxalate concentration (e.g., calcium
oxalate).
In some embodiments, a second medium may be configured to have a high calcium
composition (e.g., a high calcium second medium). For example, a high calcium
second
medium may comprise a calcium concentration of < about 800 ppm, or < about 750
ppm, or
< about 700 ppm, or < about 650 ppm, or < about 600 ppm, or < about 550 ppm,
or < about
500 ppm, or < about 450 ppm, or < about 400 ppm, or < about 350 ppm, or <
about 300 ppm,
or < about 250 ppm, or < about 200 ppm, or < about 150 ppm, or < about 100
ppm, or <
about 50 ppm. In some embodiments, a high calcium second medium may comprise a
calcium concentration of about 50 ppm to about 200 ppm, or about 50 ppm to
about 400 ppm,
or about 50 ppm to about 600 ppm, or about 100 ppm to about 800 ppm, or about
100 ppm to
about 700 ppm, or about 100 ppm to about 600 ppm, or about 100 ppm to about
500 ppm, or
about 300 ppm to about 600 ppm, or about 200 ppm to about 800 ppm. A high
calcium
second medium, according to some embodiments, may comprise a calcium
concentration of
at most about 800 ppm (e.g., 50 ppm). In some embodiments, a high calcium
second
medium may comprise a calcium concentration of at most about 600 ppm (e.g.,
50 ppm).
In some embodiments, soaking a biomass in a high calcium second medium may
effect the
equilibrium between an oxalic acid concentration and an oxalate concentration
(e.g., calcium
oxalate). For example, soaking a biomass in a high calcium second medium may
convert
oxalic acid into oxalate.
In some embodiments, a second medium may be configured to have a low calcium
composition and a low nitrogen composition (e.g., a low nitrogen and calcium
growth
medium). For example, a low nitrogen and calcium growth medium may comprise a
calcium
concentration of < about 20 ppm, or < about 18 ppm, or < about 16 ppm, or <
about 14 ppm,
or < about 12 ppm, or < about 10 ppm, or < about 9 ppm, or < about 8 ppm, or <
about 7
ppm, or < about 6 ppm, or < about 5 ppm, or < about 4 ppm, or < about 3 ppm,
or < about 2
ppm, or < about 1 ppm, or < about 0.5 ppm, or about 0 ppm. A low nitrogen and
calcium
growth medium may comprise a nitrogen concentration of < about 20 ppm, or <
about 18
ppm, or < about 16 ppm, or < about 14 ppm, or < about 12 ppm, or < about 10
ppm, or <
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about 9 ppm, or < about 8 ppm, or < about 7 ppm, or < about 6 ppm, or < about
5 ppm, or <
about 4 ppm, or < about 3 ppm, or < about 2 ppm, or < about 1 ppm, or < about
0.5 ppm, or
about 0 ppm. In some embodiments, a low nitrogen and calcium second medium may
comprise a calcium concentration of about 0 ppm to about 20 ppm, or about 0.5
ppm to about
20 ppm, or 0.5 ppm to about 15 ppm, or 0.5 ppm to about 10 ppm, or about 1 ppm
to about 9
ppm, or about 1 ppm to about 7 ppm, or about 1 ppm to about 6 ppm, or about 1
ppm to about
5 ppm, or about 3 ppm to about 6 ppm, or about 2 ppm to about 8 ppm. In some
embodiments, a low nitrogen and calcium second medium may comprise a nitrogen
concentration of about 0 ppm to about 20 ppm, or about 0.5 ppm to about 20
ppm, or 0.5 ppm
to about 15 ppm, or 0.5 ppm to about 10 ppm, or about 1 ppm to about 9 ppm, or
about 1 ppm
to about 7 ppm, or about 1 ppm to about 6 ppm, or about 1 ppm to about 5 ppm,
or about 3
ppm to about 6 ppm, or about 2 ppm to about 8 ppm. A low nitrogen and calcium
second
medium, according to some embodiments, may comprise a calcium concentration of
at most
about 10 ppm (e.g., 1 ppm). In some embodiments, a low nitrogen and calcium
second
medium may comprise a calcium concentration of at most about 5 ppm (e.g.,
0.5 ppm). A
low nitrogen and calcium second medium, according to some embodiments, may
comprise a
nitrogen concentration of at most about 10 ppm (e.g., 1 ppm). In some
embodiments, a low
nitrogen and calcium second medium may comprise a nitrogen concentration of at
most about
5 ppm (e.g., 0.5 ppm). In some embodiments, soaking a biomass in a low
nitrogen and low
calcium second medium may effect the equilibrium between an oxalic acid
concentration and
an oxalate concentration (e.g., calcium oxalate).
Soaking a biomass (e.g., FIGURE 4 454) may comprise submerging a biomass in a
second medium to form a biomass slurry, according to some embodiments. In some
embodiments, a biomass may be soaked for about 1 hour, or about 2 hours, or
about 4 hours,
or about 6 hours, or about 8 hours, or about 10 hours, or about 12 hours, or
about 16 hours, or
about 20 hours, or about 24 hours, or about 36 hours, or about 48 hours, or
about 60 hours, or
about 72 hours, or about 84 hours, or about 96 hours, or about 108 hours, or
about 120 hours,
or about 132 hours, or about 144 hours. Soaking a biomass may include
agitation, flow,
movement, spraying, or stirring of a second medium. According to some
embodiments, a
biomass slurry, including a soaked microcrop (e.g., Lemna) and a second medium
(e.g., a low
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nitrogen second medium), may be conveyed to an inclined vibrating screen where
a biomass
(e.g., microcrop) may be separated from the second medium.
According to some embodiments a biomass may be buffered in a third medium,
according to some embodiments. A third medium may comprise water (e.g., ground
water,
surface water, recycled water), distilled water, reverse osmosis water and/or
nanofiltered
water, according to some embodiments. In some embodiments, a third medium may
comprise any desired portion of recycled fluid. For example, a third medium
may comprise
at least about 10% (v/v), at least about 20% (v/v), at least about 30% (v/v),
at least about 40%
(v/v), at least about 50% (v/v), at least about 60% (v/v), at least about 70%
(v/v), at least
about 80% (v/v), or at least about 90% (v/v) recycled fluid from another stage
of the process
(e.g., a reject stream from filtration).
Buffering a pH of a biomass may comprise submerging a biomass in a third
medium
to form a biomass slurry, according to some embodiments. In some embodiments,
a biomass
may be buffered for about 1 hour, or about 2 hours, or about 4 hours, or about
6 hours, or
about 8 hours, or about 10 hours, or about 12 hours, or about 16 hours, or
about 20 hours, or
about 24 hours, or about 36 hours, or about 48 hours. According to some
embodiments, a
biomass slurry, including a buffered microcrop (e.g., Lemna) and a third
medium (e.g.,
distilled water, ground water, surface water, rain water), may be conveyed to
an inclined
vibrating screen where a biomass (e.g., microcrop) may be separated from the
third medium.
In other embodiments, a biomass (e.g., microcrop) may be separated from the
third medium
by draining.
According to some embodiments, buffering a pH of a biomass may include
changing
(e.g., raise, lower) or maintaining a pH value of the biomass. In some
embodiments,
buffering a biomass may comprise changing (e.g., raising, lowering) or
maintaining a pH
value of a biomass to below about 8.0, or below about 7.5, or below about 7.0,
or below
about 6.5, or below about 6.0, or below about 5.5, or below about 5.0, or
below about 4.5, or
below about 4.0, or below about 3.5, or below about 3Ø According to some
embodiments,
buffering a biomass may comprise changing (e.g., raising, lowering) or
maintaining a pH
value of a biomass to a range of: from about 3.0 to about 7.5., or from about
3.5 to about 7.5,
or from about 4.0 to about 7.5, or from about 4.5 to about 7.5, or from about
5.0 to about 7.5,
or from about 5.5 to about 7.5, or from about 6.0 to about 7.5, or from about
6.5 to about 7.5.
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As would be appreciated by someone having ordinary skill in the art, buffering
a biomass by
adjusting a pH value of a biomass may promote protein stability which may, in
some
embodiments, promote greater protein yields in comparison to a non-buffered
biomass.
One or more of a soaked biomass and a buffered biomass generated in one
procedure
may be stored in their respective container (e.g., soaking container,
buffering container)
before being fed to one or more downstream procedures or apparatuses. This may
accommodate different operation schedules or modes including, for example,
continuous
mode, batch mode, or multiple feeding streams to one or more downstream
procedure(s)
and/or apparatus(es). For example, in some embodiments, a biomass may be
harvested
during daylight hours and processed (e.g., soaking and/or buffering),
subsequently the
processed biomass may be further processed (e.g., lysing, separating) in
smaller batches (e.g.,
a first portion, a second portion) to accommodate the capacity limitations of
the downstream
processing machinery.
Washing a Biomass
As shown in FIGURE 4, in some embodiments, processing a microcrop or biomass
(e.g., first portion, second portion) may include a wash procedure 455 to
remove excess
growth medium, a solvent solution, debris, contaminants, microorganisms,
and/or toxins.
Washing a biomass may increase a purity and/or yield of a protein product. A
wash
procedure may disinfect and/or disinfest a biomass, reducing or removing
bacteria, fungi,
viruses, insects, and any combination thereof which are on or around the
surfaces of the
biomass. In some embodiments a wash procedure may be performed by exposing
(e.g.,
submerging, spraying) at least one surface of a biomass to a wash solution
(e.g., water,
growth medium, antimicrobial solution). A wash solution, in some embodiments,
may be
combined with a biomass (e.g., first portion, second portion) to form a
slurry.
In some embodiments, a wash solution may comprise any desired portion of
recycled
fluid. For example, a wash solution may comprise at least about 10% (v/v), at
least about
20% (v/v), at least about 30% (v/v), at least about 40% (v/v), at least about
50% (v/v), at least
about 60% (v/v), at least about 70% (v/v), at least about 80% (v/v), or at
least about 90%
(v/v) recycled from another stage of the process (e.g., recycled wash
solution, filtered
blanching solution). In some embodiments a wash solution may be an aqueous
solution or
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solvent. A wash solution may contain one or more antimicrobials, de-
infestation compounds,
fatty acids, alcohols, chlorine, oxidizing compounds, and any combination
thereof (e.g.,
ozonated water).
According to some embodiments a wash solution may be applied at an elevated
temperature and/or high pressure. A wash solution may remain in contact with a
biomass for
at least about 1 second, or for at least about 5 seconds, or for at least
about 10 seconds, or for
at least about 20 seconds, or for at least about 30 seconds, or for at least
about 1 minute, or
for at least about 5 minutes. In some embodiments, a second wash solution
(e.g., water,
ozonated water, a recycled wash solution, a filtered blanching solution may be
applied to a
biomass. A third wash solution (e.g., water, ozonated water, a recycled wash
solution, a
filtered blanching solution may be applied to a biomass, in some embodiments.
A
composition of a first wash solution, a second wash solution, and a third wash
solution may
be the same or different from one another. In some embodiments a first wash
solution may
be or may comprise a filtered blanching solution, a second wash solution may
be water, and a
third wash solution may be ozonated water. Some or all of a wash solution
(e.g., a first,
second, and/or third wash solution), in some embodiments, may be separated
from a biomass
(e.g., using an inclined screen or vibratory screen).
In some embodiments, some or all of a wash solution, second wash solution,
and/or
third wash solution may be collected and reused/recycled (e.g., a recycled
wash solution), as
shown in FIGURE 4 456. At least about 40%, or at least about 50%, or at least
about 60%, or
at least about 70%, or at least about 80%, or at least about 90%, or at least
about 95% of a
wash solution, second wash solution, and/or third wash solution (e.g., water)
separated from
the biomass may be recycled for future use as a recycled wash solution and/or
as growth
medium in the bioreactor system, according to some embodiments.
A wash solution, second wash solution, and/or third wash solution, in some
embodiments, may have or may be adjusted to have any desired pH. For example,
the pH of
a wash solution, second wash solution, and/or third wash solution may be
neutral or basic
(e.g., about 7.0, or about 7.5, or about 8.0, or about 8.5, or about 9.0, or
about 9.5, or about
10.0). According to some embodiments, the pH of a wash solution, second wash
solution,
and/or third wash solution may be from about 7.0 to about 7.5, or from about
7.5 to about 8.0,
or from about 8.0 to about 8.5, or from about 8.5 to about 9.0, or from about
9.0 to about 9.5,
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or from about 9.5 to about 10Ø The pH of a wash solution, second wash
solution, and/or
third wash solution may be from about 7.0 to about 10.0, or from about 7.0 to
about 9.5, or
from about 7.0 to about 9.0, or from about 7.0 to about 8.5, or from about 7.0
to about 8.0, or
from about 7.0 to about 7.5, in some embodiments.
A wash solution (e.g., a first, second, and/or third wash solution) may have a
temperature below room temperature (e.g., about 12 C) at the time of use.
Cooling a wash
solution, and thereby the microcrop, may improve protein recovery efficiency
and/or
decrease proteolytic activity. In some embodiments, a wash solution (e.g., a
first, second,
and/or third wash solution) may have a temperature below about 30 C, or below
about 20
C, or below about 15 C, or below about 10 C, or below about 5 C, or below
about 2 C, or
below about 1 C, or below about 0 C at the time of use. A wash solution
(e.g., a first,
second, and/or third wash solution) may have a temperature between about 0 C
and about
10 C, or between about 5 C and about 15 C, or between about 10 C and about
20 C, or
C and about 25 C, or between about 20 C and about 30 C at the time of use,
in some
15 embodiments.
Blanching a Biomass
As shown in FIGURES 3 and 4, in some embodiments, processing a microcrop or
biomass (e.g., first portion, second portion) may include blanching a
microcrop material
358/458 (e.g., a biomass) to form a blanched biomass 362/462. Blanching
358/458 may be
performed, for example, on a biomass: (1) after harvesting (e.g., as shown in
FIGURE 3); or
(2) after harvesting and washing, or (3) after harvesting and soaking, or (4)
after harvesting,
washing, and soaking (as shown in FIGURE 4), in some embodiments. According to
some
embodiments, a blanching procedure may be used either instead of or in
addition to a wash
procedure. Blanching, according to some embodiments, may decrease an ash
content, an
oxalic acid content, and/or a phenol (e.g., tannin) content of a high-
concentration protein
product (e.g., wet, flake/granule, flour). As shown in FIGURE 3A, according to
some
embodiments, blanching a biomass 358 (e.g., first portion, second portion) may
include
conveying a biomass to a blanching tray 359 and contacting the biomass with a
blanching
solution 360 to form a blanched biomass 362. In some embodiments, blanching a
biomass
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may include directing (e.g., propelling) a biomass from a first side of a
blanching tray to a
second side of the blanching tray, where the first side is opposite the second
side 361.
Conveying a biomass to a blanching tray
Conveying a biomass to a blanching tray 359 may be performed using a
conveyance
mechanism. A conveyance mechanism, in some embodiments, may comprise a
conveyor
belt or series of conveyor belts. In some embodiments, a conveyance mechanism
may
include a slide or chute wherein a biomass enters a blanching tray at least in
part due to
gravitational forces. According to some embodiments, a biomass may be conveyed
to a
blanching tray 359 at a desired feed rate. A feed rate, in some embodiments,
may be about
0.5 kg/min, or about 1 kg/min, or about 1.5 kg/min, or about 2 kg/min, or
about 3 kg/min, or
about 4 kg/min, or about 5 kg/min, or about 10 kg/min, or about 20 kg/min, or
about 50
kg/min, or about 100 kg/min, or about 150 kg/min, or about 200 kg/min, or
about 250
kg/min, or about 300 kg/min, or about 350 kg/min, or about 400 kg/min.. In
some
embodiments, a feed rate may be regulated to maintain a desired product flow
rate ratio (e.g.,
7:1).
According to some embodiments, a blanching tray may be oriented to receive a
volume of blanching solution from an applicator (e.g., FIGURE 1 114) (e.g., a
shower). A
blanching tray may be capable of containing a biomass (e.g., first portion,
second portion)
and/or a volume of blanching solution. A blanching tray may have any
dimensions and
composition suitable for its operability. According to some embodiments, a
blanching tray
may be square or rectangular in shape (e.g., when viewed from above). In some
embodiments, a blanching tray may have a first side (e.g., FIGURE 1 118)
opposite a second
side (e.g., FIGURE 1 119) and a third side opposite a fourth, where the first
side, third side,
and fourth side each have a first height and the second side has a second
height which is less
than the first height. For example, in some embodiments, a second side may be
a weir
operable to maintain a desired volume of a blanching solution in a blanching
tray. According
to some embodiments, a top edge of a second side may include one or more
notches. A
blanching tray, in some embodiments, may have a depth of about 0.5 cm, or
about 1 cm, or
about 2 cm, or about 3 cm, or about 4 cm, or about 5 cm, or about 6 cm, or
about 8 cm, or
about 10 cm, where "about" may be, for example, plus or minus 1 cm. According
to some
embodiments, a second side of a blanching tray may have a height about 0.5 cm
less than a
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height of a first side of the blanching tray, or about 1 cm less, or about 2
cm less, or about 3
cm less, or about 4 cm less, or about 5 cm less than a height of a first side,
a third side, and a
fourth side of the blanching tray, where "about" may be, for example, plus or
minus 0.5 cm.
Contacting a biomass with a blanching solution
As shown in FIGURE 3A, according to some embodiments, blanching a biomass 358
(e.g., first portion, second portion) may include contacting the biomass with
a blanching
solution 360 to form a blanched biomass 362. In some embodiments, contacting a
biomass
with a blanching solution 360 may include: (a) applying a blanching solution
to at least one
surface of a biomass (e.g., showering), (b) submerging (e.g., completely,
partially) a biomass
in a wave of blanching solution, or (c) a combination of (a) and (b).
According to some embodiments, a blanching solution may include water, ground
water, well water, distilled water, reverse osmosis water, nano-filtered
water, or any
combination thereof In some embodiments, a blanching solution may further
include at least
one dissolved solid (e.g., ash). A blanching solution may further comprise at
least one
calcium salt (e.g., calcium chloride, calcium acetate), according to some
embodiments.
Blanching a biomass with a blanching solution comprising at least one calcium
salt (e.g.,
calcium chloride, calcium acetate) may remove at least some soluble oxalic
acid from a
biomass by conversion to insoluble calcium oxalate. In some embodiments, a
calcium salt
may be selected from calcium chloride, calcium acetate, calcium carbonate,
calcium
hydroxide, or a combination thereof A blanching solution, in some embodiments,
may
include, at least in part, a blanching solution which was exposed to a
microcrop, collected,
and re-used (e.g., a recycled blanching solution FIGURE 3 369).
A blanching solution, in some embodiments, may have a temperature at the time
it
contacts a biomass of more than about 60 C, or more than about 65 C, or more
than about
70 C, or more than about 75 C, or more than about 80 C, or more than about
85 C, or
more than about 90 C, or more than about 95 C, or more than about 100 C.
Applying a blanching solution to at least one surface of a biomass
According to some embodiments, contacting a biomass with a blanching solution
360
may include applying a blanching solution to at least one surface of the
biomass (e.g.,
showering). In some embodiments, applying a blanching solution may involve
using an
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applicator to direct a volume of blanching solution onto at least one surface
of a biomass. An
applicator (e.g. FIGURE 1 114) may be any element or combination of elements
that is
capable of applying a blanching solution to at least one surface of the
biomass (e.g.,
showering). For example, in some embodiments, an applicator (e.g., FIGURE 1
114) may be
a shower. In some embodiments, an applicator may apply a blanching solution to
at least one
surface of a biomass by cascading, showering, spraying, misting, fogging,
pouring, or
dripping or otherwise dispensing a blanching solution, or any combination
thereof
According to some embodiments, a blanching solution may be applied to at least
one
surface of a biomass in a selected droplet size and/or volume. For example, in
some
embodiments, a blanching solution may be applied to at least one surface of a
biomass in a
droplet size of about 5 4, or about 10 4, or about 20 4, or about 30 4, or
about 40 4,
or about 50 4, or about 100 4, or about 200 L. In some embodiments, a
blanching
solution may be applied to at least one surface of a biomass at a rate of
about 0.5 L/min, or
about 1 L/min, or about 2 L/min, or about 3 L/min, or about 4 L/min, or about
5 L/min, or
about 6 L/min, or about 7 L/min, or about 8 L/min, or about 10 L/min, or at
least about 25
L/min, or at least about 50 L/min, or at least about 100 L/min, or at least
about 200 L/min, or
at least about 300 L/min, or at least about 500 L/min, or at least about 750
L/min, or at least
about 1000 L/min, or at least about 1500 L/min, or at least about 2000 L/min,
or at least
about 2250 L/min, or at least about 2500 L/min, in some embodiments.
Submerging a biomass in a wave of blanching solution
According to some embodiments, contacting a biomass with a blanching solution
360
may include submerging a biomass (e.g., completely, partially) in a wave of
blanching
solution within a blanching tray. A wave may include any disturbance on a top
surface of the
volume of blanching solution, such as a wave action, a ridge, a swell, or a
ripple (hereinafter
"a wave") that may be capable of depositing any quantity of blanching solution
onto a top
surface (i.e., a surface facing away from a bottom surface of blanching tray
117/217) of a
biomass.
A blanching tray (e.g., FIGURE 1 117) may be operable to contain a biomass
(e.g.,
first portion, second portion) and/or a volume of blanching solution. A
blanching tray may
have any dimensions and composition suitable for its operability. According to
some
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embodiments, a blanching tray may be square or rectangular in shape (e.g.,
when viewed
from above). In some embodiments, a blanching tray (e.g., FIGURE 1 117) may
have a first
side (e.g., FIGURE 1 118) opposite a second side (e.g., FIGURE 1 119) and a
third side
opposite a fourth, where the first side, third side, and fourth side each have
a first height and
the second side has a second height which is less than the first height. For
example, in some
embodiments, a second side may be a weir operable to maintain a desired volume
of a
blanching solution in a blanching tray. According to some embodiments, a top
edge of a
second side may include one or more notches. A blanching tray, in some
embodiments, may
have a depth of about 0.5 cm, or about 1 cm, or about 2 cm, or about 3 cm, or
about 4 cm, or
about 5 cm, or about 6 cm, or about 8 cm, or about 10 cm, where "about" may
be, for
example, plus or minus 1 cm. According to some embodiments, a second side of a
blanching
tray may have a height about 0.5 cm less than a height of a first side of the
blanching tray, or
about 1 cm less, or about 2 cm less, or about 3 cm less, or about 4 cm less,
or about 5 cm less,
where "about" may be, for example, plus or minus 1 cm. According to some
embodiments, a
blanching tray (e.g., FIGURE 1 117) may be oriented to receive a volume of
blanching
solution exiting an applicator (e.g., FIGURE 1 114 (e.g., a shower).
In some embodiments, a wave of blanching solution within a blanching tray may
be
generated by a vibrating blanching tray mechanism comprising a blanching tray
and a
vibratory mechanism (e.g., FIGURES 1 and 2). According to some embodiments, a
vibratory
mechanism (e.g., FIGURE 1 120) may be capable of vibrating a blanching tray
(e.g.,
FIGURE 1 117) to generate a net motion (e.g., a wave) of a volume of blanching
solution
within the blanching tray. In some embodiments, vibratory mechanism (e.g.,
FIGURE 1 120)
may be directly connected to or incorporated into a design of blanching tray
(e.g., FIGURE 1
117). In other embodiments, a vibratory mechanism may be adjacent to a
blanching tray.
For example, as shown in FIGURE 2, a vibratory mechanism 220 may include a
platform
suspended on a system of springs 221 such that a blanching tray 217 may be
attached (e.g.,
fixedly, removably) to the platform and thereby exposed to vibrational forces
(e.g.,
oscillation) generated. A vibratory mechanism, in some embodiments, may be
installed
directly on a platform being vibrated or indirectly coupled to the platform
being vibrated. In
some embodiments, a vibratory mechanism may comprise one or more one-axis
motors, one
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or more stepper motors, one or more servo motors, one or more axis motor
drives, one or
more weights (e.g., balanced, unbalanced), or any combination thereof
In some embodiments, a wave of blanching solution within a blanching tray may
be
generated by a vibratory mechanism (e.g., FIGURE 1 120) producing a net motion
of the
volume of blanching solution. A wave may be capable of depositing any quantity
of
blanching solution onto a top surface (i.e., a surface facing away from a
bottom surface of
blanching tray 117/217) of a biomass. A wave of a volume of blanching solution
may result
in a biomass being submerged (e.g., completely, partially). Submerging a
biomass in a wave
of blanching solution may include a top surface (i.e., a surface facing away
from a bottom
surface of blanching tray) of a biomass being covered by a quantity of
blanching solution
106/206 (e.g., repeatedly covered, partially covered). For example, submerging
a biomass in
a wave of blanching solution may include a top surface of a biomass being
repeatedly
exposed to a volume of blanching solution as one or more waves (i.e., a
disturbance of the
blanching solution (e.g., one or more waves) roll across a blanching tray.
Submerging a
biomass in a wave of blanching solution may result in more uniform blanching
of the
biomass.
In some embodiments, contacting a biomass with a blanching solution 360 may
include both (a) applying a blanching solution to at least one surface of a
biomass (e.g.,
showering) and (b) submerging (e.g., completely, partially) a biomass in a
wave of blanching
solution.
Directing a biomass across a blanching tray
According to some embodiments, contacting a biomass with a blanching solution
360
may include directing (e.g., propelling) a biomass from a first side (e.g.,
FIGURE 1 118) of a
blanching tray (e.g., FIGURE 1 117) to a second side (e.g., FIGURE 1 119) of
the blanching
tray, where the first side is opposite the second side. In some embodiments, a
net motion of a
volume of blanching solution generated by a vibratory mechanism (e.g., FIGURE
1 120) may
generate a motive force capable of directing (e.g., propelling) biomass from a
first side of
blanching tray to a second side of blanching tray, where the first side is
opposite the second
side. In some embodiments, a second side of a blanching tray may have a height
less than a
height of a first side of the blanching tray (e.g., a weir); thereby allowing
a volume of
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blanching solution and/or a mass of biomass to exit the blanching tray after
it is transported
from the first side (e.g., FIGURE 1 118) to the second side (e.g., FIGURE 1
119) of the
blanching tray. According to some embodiments, a mass of biomass and/or a
volume of
blanching solution may exit a blanching tray after being propelled from a
first side of
blanching tray to a second side of blanching tray.
In some embodiments, directing (e.g., propelling) a biomass from a first side
of a
blanching tray to a second side of the blanching tray, where the first side is
opposite the
second side, may involve using gravity, paddle wheels, bubbling, submerged or
surface water
jets, submerged mixers, a vibratory mechanism, or any combination thereof as a
propulsion
mechanism.
Blanching conditions and flow rate
According to some embodiments, a biomass may be contacted with a blanching
solution (e.g., FIGURE 3A 360) for up to about 20 seconds (sec), or up to
about 30 sec, or up
to about 40 sec, or up to about 50 sec, or up to about 1 min, or up to about 1
min 15 sec, or up
to about 1 min 30 sec, or up to about 1 min 45 sec, or up to about 2 min, or
up to about 2 min
30 sec or up to about 3 min, or up to about 4 min, or up to about 5 min, or up
to about 6 min,
or up to about 7 min, or up to about 8 min, or up to about 9 min, or up to
about 10 min,
according to some embodiments. In some embodiments, a biomass may be contacted
with a
blanching solution (e.g., FIGURE 3A 360) for about 20 sec to about 40 sec, or
about 30 sec
to about 45 sec, or about 30 sec to about 1 min, or about 30 sec to about 1
min 30 sec, or
about 30 sec to about 2 min, or about 30 sec to about 5 min, or about 1 min to
about 5 min, or
about 1 min to about 5 min, or about 1 min to about 10 min, or about 30 sec to
about 10 min,
where "about" may be, for example, plus or minus 10%.
In some embodiments, a biomass may be contacted with a blanching solution
having a
temperature of about 85 C for about 40 sec.
A blanching solution, in some embodiments, may change temperature while
contacting a biomass. For example, according to some embodiments, a biomass
may be
contacted by a blanching solution having an initial temperature of between
about 92 C and
about 94 C where the contact continues for a period of about 40 sec at which
point the
blanching solution may have a final contact temperature of between about 75 C
and about
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77 C. In some embodiments, a blanching solution, in some embodiments, may
have an
initial temperature (e.g., a temperature at a time where the blanching
solution first contacts a
biomass) of more than about 60 C, or more than about 65 C, or more than
about 70 C, or
more than about 75 C, or more than about 80 C, or more than about 85 C, or
more than
about 90 C, or more than about 95 C, or more than about 100 C. A blanching
solution, in
some embodiments, may have a final contact temperature (e.g., a temperature at
a time where
the biomass exits the blanching tray) of less than about 60 C, or less than
about 65 C, or
less than about 70 C, or less than about 75 C, or less than about 80 C, or
less than about
85 C, or less than about 90 C, or less than about 95 C, or less than about
100 C.
In some embodiments, blanching a biomass 358 may be performed at a product
flow
rate ratio calculated by dividing a pump rate by a feed rate. For example, in
some
embodiments, a blanching solution may be propelled at a pump rate of 28 liters
per min
(L/min) and biomass may be conveyed at a feed rate of 4 kg per min (kg/min)
resulting in a
product flow rate ratio of 7:1. According to some embodiments, blanching a
biomass 358
may have a product flow rate ratio of about 10:1, or about 9:1, or about 8:1,
or about 7.5:1,
or about 7:1õ or about 6.5:1, or about 6:1, or about 5.5:1, or about 5:1, or
about 4.5:1, or
about 4:1, or about 3.5:1, or about 3:1, or about 2.5:1, or about 2:1, or
about 1.5:1, or about
1:1, according to some embodiments.
Monitoring a blanching process
According to some embodiments, blanching a biomass may include monitoring one
or
more of the following: a volume of blanching solution within a blanching tray
(e.g., FIGURE
1 117); a mass of a biomass within a blanching tray; a volume of a blanching
solution exiting
a blanching tray; a mass of a biomass exiting a blanching tray; a temperature
of a blanching
solution within a blanching tray (e.g., average temperature, at specific
locations); a
temperature of a blanching solution exiting a blanching tray; a rate of net
motion; a height
and frequency of wave action; a dissolved solids content (e.g., ash) of a
blanching solution.
In some embodiments, blanching a biomass may include adjusting one or more of
the
following conditions in response to monitored conditions: a rate of blanching
solution exiting
an applicator (e.g., FIGURE 1 114), a temperature of a blanching solution
applied onto a
biomass, a rate of net motion, a dilution rate (i.e., rate of diluting a
separated solution), or any
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combination thereof In some embodiments, monitoring a blanching process may
include a
monitoring device (e.g., a first gauge 122/222) communicating with a central
control system
or one or more components of a blanching apparatus (e.g., FIGURE 1 100) to
maintain or
adjust a desired product flow rate ratio (e.g., 7:1) or a dilution rate (e.g.,
2.5:1).
Settling A Blanched Biomass
As shown in FIGURE 4, according to some embodiments, a method may include
settling a blanched biomass 463. In some embodiments, settling a blanched
biomass 463 may
occur in a settling tank (e.g., FIGURE 2 224). According to some embodiments,
after being
propelled from a first side of blanching tray to a second side of blanching
tray, where the first
side is opposite the second side, a blanched biomass and/or a volume of
blanching solution
may exit a blanching tray and enter a settling tank (e.g., FIGURE 2 224). A
settling tank, in
some embodiments, may be, directly or indirectly, connected to blanching tray
in such a way
that a blanched biomass and a volume of blanching solution may flow into
settling tank (e.g.,
gravity flow, propulsion).
Settling a blanched biomass 464 may allow contaminants and/or debris to become
dislodged from a blanched biomass thereby generating a purer product. In some
embodiments, settling a blanched biomass may involve gravitational removal of
non-buoyant
solids. Non-buoyant solids, in some embodiments, may include fresh water
arthropods or
molluscs (e.g., gammarus and snails).
A settling tank (e.g., FIGURE 2 224) may have any dimensions and/or
composition
suitable for its operability. According to some embodiments, a settling tank
(e.g., FIGURE 2
224) may be square or rectangular in shape. In some embodiments, a settling
tank may have
a first side (e.g., FIGURE 2 225) opposite a second side (e.g., FIGURE 2 226)
and a third
side opposite a fourth, where the first side, third side, and fourth side each
have a first height
and the second side has a second height which is less than the first height.
For example, in
some embodiments, a second side may be a weir operable to maintain a desired
volume of a
blanching solution in a blanching tray. According to some embodiments, a top
edge of a
second side may include one or more notches. A settling tank (e.g., FIGURE 2
224), in some
embodiments, may have a depth of about 5 cm, or about 7.5 cm, or about 10 cm,
or about
12.5 cm, or about 15 cm, or about 17.5 cm, or about 20 cm, or about 22.5 cm,
or about 25 cm,
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or about 30 cm, or about 35 cm, or about 40 cm, or about 45 cm, or about 50
cm, where
"about" may represent plus or minus 2.5 cm. In some embodiments, a settling
tank (e.g.,
FIGURE 2 224) may include one or more sloping sides and/or a sloping bottom
which may
aid in removal of contaminants, debris, or non-buoyant solids that sink below
a surface of a
settling solution.
In some embodiments, settling a blanched biomass (e.g., FIGURE 4 463) may
include
exposing at least one surface of a blanched biomass to a settling solution. A
settling solution
may include any liquid having characteristics which permit contaminants and/or
debris to
sink away from a top surface of the settling solution. According to some
embodiments, a
settling solution may comprise a blanching solution. A settling solution, in
some
embodiments, may comprise water, ground water, well water, distilled water,
deionized
water, reverse osmosis water, nanofiltered water, ultra-filtered water, or any
combination
thereof In some embodiments, a settling solution may be selected to have a
specific
viscosity.
Settling a blanched biomass 463, in some embodiments, may include filtering
one or
more non-buoyant solids from a settling tank. In some embodiments, a settling
tank (e.g.,
FIGURE 2 224) may include filters or screens that may aid in filtering a
biomass from debris,
contaminants, and/or non-buoyant solids. For example, in some embodiments, a
settling tank
may include a screen across a surface of the settling tank but below a top
surface of a settling
solution. A screen, in some embodiments, may include a mesh size small enough
to retain a
biomass but large enough to allow at least some debris, contaminants, and/or
non-buoyant
solids to pass through. In some embodiments, a screen may be capable of
vibratory motion
such that a blanched biomass may be transported from a first side 225 of a
settling tank to a
second side 226 of the settling tank, where the first side and the second side
are opposite.
According to some embodiments, settling a blanched biomass (e.g., FIGURE 4
463)
may include debris, contaminants, and/or non-buoyant solids settling to a
bottom of a settling
tank. Debris, contaminant, and/or non-buoyant solids may be recycled (e.g.,
used in a
microcrop cultivation system, fish food), in some embodiments.
According to some embodiments, settling a blanched biomass (e.g., FIGURE 4
463)
may include cooling a blanched biomass. For example, a settling solution
within settling tank
(e.g., FIGURE 2 224) may have a temperature less than a temperature of a
blanching solution
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(e.g., FIGURE 2 206) (e.g., below about 60 C) thus when at least one surface
of a blanched
biomass is exposed to the settling solution the blanched biomass cools. In
some
embodiments, a settling solution may have a temperature below about 90 C, or
below about
80 C, or below about 70 C, or below about 60 C, or below about 50 C, or
below about
40 C, or below about 30 C, or below about 20 C at the time of use. A
settling solution, in
some embodiments, may have a temperature between about 20 C and about 80 C,
or
between about 40 C and about 80 C, or between about 40 C and about 60 C,
or between
about 20 C and about 40 C, or between about 20 C and about 30 C. at the
time of use.
In some embodiments, settling a blanched biomass (e.g., FIGURE 4 463) may
include
monitoring a settling tank (e.g., using a second gauge FIGURE 2 229). In some
embodiments, monitoring a settling tank may measuring one or more of the
following: a
volume of a settling solution within settling tank; a mass of a blanched
biomass within a
settling tank; a volume of a settling solution exiting a settling tank; a mass
of a blanched
biomass exiting a settling tank; a temperature of a settling solution within a
settling tank (e.g.,
average temperature, at specific locations); a temperature of a settling
solution exiting a
settling tank; a dissolved solids content (e.g., ash) of a settling solution.
In some
embodiments, monitoring a settling tank (e.g., using a second gauge FIGURE 2
229) may
include a monitoring mechanism (e.g., a second gauge FIGURE 2 229)
communicating with
a central control system and/or one ore more elements of a blanching apparatus
(e.g.,
FIGURE 2 200). For example, a monitoring mechanism (e.g., a second gauge
FIGURE 2
229) may communicate with (e.g., directly, through a central control system) a
heating
element (e.g., FIGURE 2 212), an applicator (e.g., FIGURE 2 214), a vibratory
mechanism
(e.g., FIGURE 2 220), a tank (e.g., FIGURE 2 236), a pump and valve system
(e.g.,
FIGURE 2 248), or any combination thereof such that various conditions may be
adjusted.
According to some embodiments, settling a blanched biomass (e.g., FIGURE 4
463) may
include a monitoring mechanism (e.g., a second gauge FIGURE 2 229)
communicating with
a central control system and/or one ore more elements of a blanching apparatus
(e.g.,
FIGURE 2 200) to maintain or adjust a desired product flow rate ratio (e.g.,
7:1) or a dilution
rate (e.g., 2:1).
In some embodiments, settling a blanched biomass (e.g., FIGURE 4 463) may
include
propulsion of a blanched biomass (e.g., first portion, second portion) from a
first side of a
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settling tank (e.g., FIGURE 2 225) to a second side of the settling tank
(e.g., FIGURE 2 226),
where the first side and the second side are opposite one another. In some
embodiments,
propulsion of a blanched biomass may include use of a propulsion mechanism of
a settling
tank. For example, a propulsion mechanism of a settling tank may include
gravity, paddle
wheels, bubbling, submerged or surface water jets, submerged mixers, a
vibratory
mechanism, or any combination thereof, according to some embodiments. In some
embodiments, a propulsion mechanism may include a pump operable to pump a
settling
solution from an entry point to an exit point of settling tank.
According to some embodiments, directing (e.g., propelling) a biomass from a
first
side of settling tank to a second side of settling tank may result in a mass
of biomass and/or a
volume of settling solution exiting the settling tank and entering a
dewatering mechanism
(e.g., FIGURE 2 234). A dewatering mechanism may be, directly or indirectly,
connected to
a blanching tray or a settling tank in such a way that a mass of biomass, a
volume of
blanching solution, and/or a volume of settling solution may flow into the
dewatering
mechanism (e.g., gravity flow, propulsion), in some embodiments.
Dewatering a Blanched Biomass
As shown in FIGURES 3 and 4, a method 300/400 may include dewatering a
blanched biomass 364/464. Dewatering a blanched biomass may occur after (1)
blanching a
biomass (e.g., FIGURE 3) or (2) after blanching a biomass and settling a
blanched biomass,
(e.g., FIGURE 4), according to some embodiments.
Dewatering a blanched biomass, in some embodiments, may include separating a
blanching solution, a settling solution, or any combination (individually and
collectively "a
separated solution") (e.g., FIGURES 1 and 2 135/235) from a blanched biomass.
In some
embodiments, dewatering a blanched biomass may involve using a dewatering
mechanism,
including, for example, gravity separation, draining, an inclined screen, a
vibratory screen,
filtration, a decanter centrifuge, a belt press, a fan press, a rotary press,
a screw press, a filter
press, a finisher press, or any combination thereof
According to some embodiments, after being propelled from a first side of a
settling
tank to a second side of settling tank, where the first side is opposite the
second side, a mass
of blanched biomass and/or a volume of settling solution may exit the settling
tank and enter
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a dewatering mechanism. In some embodiments, after being propelled from a
first side of a
blanching tray to a second side of blanching tray, where the first side is
opposite the second
side, a mass of blanched biomass and/or a volume of a blanching solution may
exit the
blanching tray and enter a dewatering mechanism. In some embodiments, a method
may
include depositing a blanched biomass into a dewatering mechanism without
traveling from a
first side to a second side of a blanching tray, a settling tank, or a rinsing
mechanism. For
example, in some embodiments, a blanching tray containing a biomass and a
blanching
solution may be directly emptied (e.g., chute feed, gravity feed) into a
dewatering mechanism
without departing from the scope of the instant disclosure.
Rinsing a Blanched Biomass
According to some embodiments, a method may include rinsing (e.g., FIGURE 4
465) a
blanched biomass. In some embodiments, rinsing (e.g., FIGURE 4 465) a blanched
biomass
may remove unwanted dissolved solids from a blanched biomass.
According to some embodiments, rinsing a blanched biomass may include exposing
at
least one surface of the blanched biomass to a rinsing solution. According to
some
embodiments, exposing at least one surface of a blanched biomass to a rinsing
solution may
involve depositing a rinsing solution through a sprinkler head onto at least
one surface of a
biomass, where the biomass is located on a vibratory screen, and operating the
vibratory
screen to remove at least some of the rinsing solution. Exposing at least one
surface of a
blanched biomass to a rinsing solution may include floating or submerging a
blanched
biomass in a rinsing tank (e.g., FIGURE 2 230), according to some embodiments.
A rinsing
tank may have any suitable dimensions or shape. In some embodiments, a rinsing
tank may
have a depth of about 5 cm, or about 7.5 cm, or about 10 cm, or about 12.5 cm,
or about 15
cm, or about 17.5 cm, or about 20 cm, or about 22.5 cm, or about 25 cm, or
about 30 cm, or
about 35 cm, or about 40 cm, or about 45 cm, or about 50 cm, where "about" may
represent
plus or minus 1 cm.
According to some embodiments, a rinsing solution may include water, distilled
water, reverse osmosis water, nanofiltered water, a blanching solution, a
settling solution, a
recycled blanching solution, a recycled settling solution, a recycled rinsing
liquid, or any
combination thereof According to some embodiments, a rinsing solution may be
sterilized
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(e.g., UV radiation, filtration, heating). In some embodiments, a dilution
solution (e.g.,
FIGURE 2 208) may be used as a rinsing solution.
In some embodiments, rinsing (e.g., FIGURE 4 465) a blanched biomass may lower
a
temperature of the blanched biomass. For example, rinsing a blanched biomass
may include
exposing at least one surface of a blanched biomass to a rinsing solution
having a temperature
below a temperature of the blanched biomass. In some embodiments, a rinsing
solution may
have a temperature below room temperature (e.g., about 12 C) at the time of
use. In some
embodiments, a rinsing solution may have a temperature below about 50 C, or
below about
40 C, or below about 30 C, or below about 20 C, or below about 15 C, or
below about
10 C, or below about 5 C, or below about 2 C, or below about 1 C, or below
about 0 C at
the time of use. A rinsing solution may have a temperature between about 0 C
and about
10 C, or between about 5 C and about 15 C, or between about 10 C and about
20 C, or
C and about 25 C, or between about 20 C and about 30 C, or between about 0
C and
about 50 C at the time of use, in some embodiments.
15 In some embodiments, rinsing a blanched biomass may include directing
(e.g.,
propelling) a blanched biomass from a first side of a rinsing mechanism (e.g.,
vibratory
screen, rinsing tank) to a second side of the rinsing mechanism, where the
first side and the
second side are opposite one another. According to some embodiments directing
(e.g.,
propelling) a blanched biomass may include using gravity, paddle wheels,
bubbling,
submerged or surface water jets, submerged mixers, a vibratory mechanism, or
any
combination thereof
According to some embodiments, rinsing a blanched biomass may further include
dewatering a rinsed blanched biomass to remove excess liquid. Dewatering a
rinsed blanched
biomass may be performed using a dewatering mechanism, including, for example,
gravity
separation, draining, an inclined screen, a vibratory screen, filtration, a
decanter centrifuge, a
belt press, a fan press, a rotary press, a screw press, a filter press, a
finisher press, or any
combination thereof
Collecting a Separated Solution
As shown in FIGURES 3 and 4, in some embodiments, a method may include
collecting 366/466 a separated solution (e.g., FIGURE 2 235). A separated
solution, in some
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embodiments, may include a blanching solution, or a settling solution, or a
rinsing solution,
or any combination thereof Collecting a separated solution 466 may involve
storing (e.g.,
transiently, extended) the separated solutions in a collection tank, in some
embodiments. A
collection tank (e.g., FIGURE 2 236) may have any size, shape, dimensions, or
composition
suitable for collecting and retaining liquid. In some embodiments, a
collection tank may be
the same as a source (e.g., FIGURE 1 110) (i.e., a single container serves as
both a source and
a collection tank). A separated solution within a collection tank may be
stationary or moving
(e.g., agitation, propulsion).
According to some embodiments, collecting 366/466 a separated solution may
include
monitoring a separated solution. According to some embodiments, monitoring a
separated
solution may include monitoring a composition (e.g., total dissolved solids)
and/or
temperature of a separated solution. Monitoring a composition of a separated
solution may
include monitoring one or more of the following: total dissolved solids, total
solids, turbidity,
electrical conductivity, nutrient (e.g., nitrogen) composition, salinity, pH,
in some
embodiments.
In some embodiments, collecting 366/466 a separated solution may include
maintaining or adjusting a composition (e.g., total solids, turbidity) of a
separated solution.
In some embodiments, a method may include communicating with (e.g., through a
collection
tank gauge FIGURE 2 238) with one or more components of a blanching apparatus
(e.g., a
pump and valve system, a dilution tank), either directly or through a central
control system
(e.g., FIGURE 2 202), to regulate a composition of a separated solution (e.g.,
by adjusting a
dilution rate). In some embodiments, a method may include communicating with
(e.g.,
through a collection tank gauge FIGURE 2 238) one or more components of a
blanching
apparatus (e.g., a pump and valve system, a dilution tank), either directly or
through a central
control system (e.g., FIGURE 2 202), to maintain and/or adjust a desired
product flow rate
ratio (e.g., 7:1).
Maintaining or adjusting a composition of a separated solution, in some
embodiments,
may include maintaining or adjusting a total solids content of a volume of
separated solution
and/or a volume of a blanching solution in a collection tank at/to a value of
less than 0.5%, or
less than 1% (w/w) or less than 2% (w/w), or less than 4% (w/w), or less than
6% (w/w) or
less than 8% (w/w), or less than 10% (w/w). According to some embodiments,
maintaining
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or adjusting a composition of a separated solution may include maintaining or
adjusting a
turbidity value (e.g., relative to absorbance of a 500 nm light source where
1.0 is equivalent
to 10% absorbance and 10.0 is equivalent to 100% absorbance) of a volume of
separated
solution 135/235 and/or a volume of a blanching solution 106/206 at a value of
less than
about 0.5, or less than about 0.75, or less than about 1.0, or less than about
1.25, or less than
about 1.5, where about may represent plus or minus 5%. In some embodiments,
maintaining
or adjusting a composition of a separated solution may include maintaining or
adjusting an
electrical conductivity value of the separated solution at/to a value of less
than about 2000
[tS/cm, or less than about 2500 [tS/cm, or less than about 3000 [tS/cm, or
less than about
3500 [tS/cm, or less than about 4000 [tS/cm, or less than about 4500 [tS/cm,
or less than
about 5000 [tS/cm, or less than about 5500 [tS/cm, or less than about 6000
[tS/cm, where
"about" may represent plus or minus 250 [tS/cm.
In some embodiments, maintaining or adjusting a composition of a separated
solution
may include diluting a separated solution. Dilution of a separated solution
(e.g., FIGURE 1
135) may be desirable to adjust a composition of the separated solution (e.g.,
dissolved solids
content, turbidity). A diluted separated solution may be recycled as a
blanching solution
(e.g., FIGURE 4 368), as a wash solution, as a settling solution, as a rinsing
solution, or any
combination thereof, in some embodiments. In some embodiments, diluting a
separated
solution may involve discarding a volume of discard solution (e.g., FIGURE 2
243) from a
collection tank and imputing a volume (e.g., an equal volume) of a dilution
solution (e.g.,
FIGURE 2 208). A discard solution may have a volume equal to a volume of
dilution
solution necessary to achieve a desired composition of dissolved solids (e.g.,
ash), according
to some embodiments. In some embodiments, a discard solution may have a volume
higher
than a volume of dilution solution necessary to achieve a desired composition
of dissolved
solids (e.g., ash). A rate of discarding a volume of separated solution from a
collection tank
may be regulated by a collection tank gauge (e.g., total tank volume), in some
embodiments.
In some embodiments, a discard solution (e.g., FIGURE 1 143) may be recycled
as a
growth medium in the cultivation of a microcrop. According to some
embodiments, a
dilution solution may be stored in a dilution source. A dilution solution
(e.g., FIGURE 1
108), according to some embodiments, may include water, ground water, well
water, distilled
water, deionized water, reverse osmosis water, nanofiltered water, ultra-
filtered water, or any
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combination thereof A dilution source (e.g., FIGURE 1 142), in some
embodiments, may
include a holding tank, a well, a water line, or any other container or system
capable of
holding a liquid. In some embodiments, diluting a separated solution may
include discarding
a volume of separated solution (i.e., a discard solution 143/243) from a
collection tank.
According to some embodiments, a separated solution (e.g., FIGURE 1 135)
and/or a
blanching solution (e.g., FIGURE 1 106) in a collection tank (e.g., FIGURE 1
136) may be
diluted to comprise a desired composition of dissolved solids (e.g., ash)
and/or total solids.
In some embodiments, a volume of separated solution and/or a volume of a
blanching
solution in a collection tank may be diluted to have a total solids content at
a value of less
than 0.5% (w/w), or less than 1% (w/w) or less than 2% (w/w), or less than 4%
(w/w), or less
than 6% (w/w) or less than 8% (w/w), or less than 10% (w/w). According to some
embodiments, a separated solution in collection tank may be diluted to have a
turbidity value
(e.g., relative to absorbance of a 500 nm light source where 1.0 is equivalent
to 10%
absorbance and 10.0 is equivalent to 100% absorbance) of a volume of separated
solution
135/235 and/or a volume of a blanching solution 106/206 at a value of less
than about 0.5, or
less than about 0.75, or less than about 1.0, or less than about 1.25, or less
than about 1.5,
where about may represent plus or minus 5%. In some embodiments, a separated
solution
and/or a blanching solution in a collection tank may be diluted to have an
electrical
conductivity value of less than about 2000 0/cm, or less than about 2500
S/cm, or less than
about 3000 S/cm, or less than about 3500 S/cm, or less than about 4000
S/cm, or less
than about 4500 S/cm, or less than about 5000 S/cm, or less than about 5500
S/cm, or
less than about 6000 S/cm, where "about" may represent, for example, plus or
minus 250
S/cm.
In some embodiments, a separated solution in collection tank may be diluted
relative
to a biomass feed rate. According to some embodiments, a separated solution in
collection
tank may be diluted relative to a feed to dilution ratio of about 4:1, or
about 3.5:1, or about
3:1, or about 2.5:1, or about 2:1, or about 1.5:1, or about 1:1.
Diluting a separated solution may include subjecting a donor stream and a
recipient
stream to a heat exchanger. According to some embodiments, a heat exchanger
(e.g.,
FIGURE 1 144) (e.g., thermal energy exchange mechanisms) may decrease an
overall energy
input required for production of high-concentration protein product (e.g.,
protein flake) from
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a microcrop (e.g., Lemna). According to some embodiments, a heat exchanger may
include a
flow system wherein a stream of discard solution (e.g., FIGURE 1 143) from
collection tank
(e.g., FIGURE 1 136) (i.e., a donor stream) and a dilution solution stream
(e.g., FIGURE 1
108) (i.e., recipient stream) are adjacent such that thermal energy exchange
may occur. In
some embodiments, a dilution solution stream (i.e., a recipient stream) may
have a cooler
temperature and thereby a lower thermal energy than a donor stream (e.g., a
discard solution
stream which retains heat from a blanching solution). According to some
embodiments, a
heat exchanger may include a flow system (e.g., a series of pipes composed of
conductive
material) such that a dilution solution stream (i.e., a recipient stream) may
absorb at least
some thermal energy from a discard solution stream (i.e., a donor stream). In
some
embodiments, a heat exchanger may result in increasing a temperature of a
dilution solution
stream and/or a diluted separated solution in tank. In some embodiments, a
heat exchanger
may reduce an amount of energy required for heating a recycled solution in
heating element
(e.g., FIGURE 1 112).
According to some embodiments, collecting a separated solution may include
filtering
a separated solution. Filtering a separated solution may include coarse
filtration (e.g., gravity
filtration, vibratory screen filtration), fine filtration (e.g.,
microfiltration, ultrafiltration,
nanofiltration, reverse osmosis filtration), or any combination thereof A
filtered separated
solution may be recycled as a wash solution, as a growth medium in the
cultivation of a
microcrop, as a blanching solution, as a settling solution, as a rinsing
solution, or any
combination thereof In some embodiments, a blanching waste (e.g., retentate
from a
filtration method) may be recycled as part of a growth medium (e.g., as a
nutrient source) in a
cultivation of a microcrop.
A collected separated solution (e.g., diluted, filtered, monitored, subject to
heat
exchange, or any combination thereof) may be recycled as a wash solution, as a
growth
medium in the cultivation of a microcrop, as a blanching solution, as a
settling solution, as a
rinsing solution, or any combination thereof
Reducing a Moisture Content of a Blanched Biomass
In some embodiments a method may further include reducing a moisture content
of a
blanched biomass. According to some embodiments, a moisture content of a
blanched
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biomass may be reduced without cooling the blanched biomass. Reducing a
moisture content
of a blanched biomass may reduce capital and operational expenditures, for
example, by
reducing the energy needed to dry an end protein product (e.g., protein
concentrate
flake/granule).
In some embodiments an evaporation process may be used to reduce a moisture
content of a blanched biomass. Evaporation may be performed by, for example, a
thermal
(evaporative) means such as: a rising film evaporator, a falling film
evaporator, a natural
circulation evaporator (vertical or horizontal), an agitated-film evaporator,
a multiple-effect
evaporator, by vacuum evaporation, or any combination thereof Heat may be
supplied
directly into the evaporator, or indirectly through a heat jacket. Heat may
either come from a
raw source (e.g., combustion of natural gas, steam from a boiler) or from a
waste heat stream
(e.g., dryer exhaust) or from heat transferred by cooling the input stream.
According to some embodiments, a moisture content of a blanched biomass may be
reduced using gravity separation, draining, an inclined screen, a vibratory
screen, filtration, a
decanter centrifuge, a belt press, a fan press, a rotary press, a screw press,
a filter press, a
finisher press, or any combination thereof
In some embodiments an antioxidant (e.g., rosemary extract, Duralox , Phyt-O-
Blend
CA) may be mixed with a blanched biomass prior to drying to improve shelf life
of product
(e.g., shelf life of a packaged product).
Solvent Extraction of a Blanched Biomass
According to some embodiments, a method of blanching a biomass to generate a
high-concentration protein product may include a solvent extraction procedure
to generate a
solvent washed protein product.
A solvent washed protein product, in some embodiments, may have increased
protein
purity when compared to a protein product that was not subjected to a solvent
extraction
procedure. A solvent extraction procedure may decolor a blanched biomass,
according to
some embodiments, resulting in a solvent washed protein product having a
reduced
chlorophyll content (e.g., visually perceivable reduction in green coloration)
compared to
unwashed counterparts. In some embodiments, a solvent extraction procedure may
reduce a
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fat content of a protein concentrate (e.g., wet, flake/granule, flour). The
reduction of a fat
content may increase the shelf-life of a high-concentration protein product.
Solvent extraction of a blanched biomass, in some embodiments, may comprise
exposing (e.g., submerging, spraying, dripping) at least one surface of the
blanched biomass
to a solvent solution (e.g., ethanol, methanol, acetone). A solvent solution,
in some
embodiments, may be combined with a blanched biomass (e.g., first portion,
second portion)
to form a slurry. According to some embodiments, a solvent extraction
procedure may
include exposing (e.g., submerging, spraying, dripping, slurry) at least one
surface of a
blanched biomass to a solvent solution for at least about 5 sec., at least
about 15 sec., at least
about 30 sec., at least about 45 sec., at least about 1 min., at least about 2
min., at least about
3 min., at least about 5 min., at least about 10 min., at least about 20 min.,
at least about 30
min., at least about 40 min., at least about 50 min., at least about 1 hour,
at least about 2
hours, at least about 3 hours, at least about 4 hours, at least about 5 hours,
at least about 6
hours, at least about 12 hours, or at least about 24 hours. A solvent
extraction procedure, in
some embodiments, may include moving (e.g., agitating, stirring, propelling)
at least a
portion of a solvent solution at a specified time, intermittently, or
continually.
In some embodiments a solvent solution may include one or more alcohols (e.g.,
ethanol, methanol, propanol, isopropanol, glycerol), acetone, dichloromethane,
ethyl acetate,
hexane, ketones, or combinations thereof A solvent solution may comprise at
least about
10% (v/v), at least about 20% (v/v), at least about 30% (v/v), at least about
40% (v/v), at least
about 50% (v/v), at least about 60% (v/v), at least about 70% (v/v), at least
about 80% (v/v),
or at least about 90% (v/v) of one or more alcohols (e.g., ethanol, methanol,
propanol,
isopropanol, glycerol), acetone, dichloromethane, ethyl acetate, hexane,
ketones, or
combinations thereof
In some embodiments, a solvent may be recovered and recycled. Furthermore,
according to some embodiments, a chlorophyll byproduct and/or a fat byproduct
extracted
from a blanched biomass by solvent extraction may be recovered from the
solvent.
A solvent washed protein product, in some embodiments, may have a reduced fat
content (e.g., about 2% of a protein concentrate flake/granule or less by
weight) and/or a
reduced chlorophyll content (e.g., visually perceivable reduction in green
coloration)
compared to unwashed counterparts. In some embodiments, a solvent washed
protein
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product may appear colorless, white, substantially white, or have reduced
green coloration.
A solvent washed protein product, in some embodiments, may exhibit improved
taste, color,
shelf life (e.g., reduced oxidation of fats), protein density, malleability,
and combinations
thereof
In some embodiments, a solvent washed protein product may have a fat content
comprising lower than about 50%, or lower than about 40%, or lower than about
30%, or
lower than about 25%, or lower than about 20%, or lower than about 15%, or
lower than
about 10%, or lower than about 5%, or lower than about 4%, or lower than about
3%, or
lower than about 2%, or lower than about 1% by weight of a dry protein
concentrate (e.g.,
flake, granule, flour). According to some embodiments, a solvent washed
protein product
may have a fat content comprising from about 1% to about 10%, or from about
10% to about
20%, or from about 20% to about 30%, or from about 30% to about 40%, or from
about 40%
to about 50% by weight of the a dry protein concentrate (e.g., flake, granule,
flour).
In some embodiments, a solvent washed protein product may have a fat content
comprising a percentage of a dry protein concentrate (e.g., flake, granule,
flour) by weight of
less than about 15 % (w/w) , less than about 10% (w/w), or less than about 6%
(w/w), or less
than about 4% (w/w), or less than about 2% (w/w), or less than about 1%, or
less than about
0.5%, or less than about 0.2%, or less than about 0.1%. In some embodiments, a
solvent
washed protein product may have a fat content comprising from about 0.1% to
about 0.2% by
weight of a dry protein concentrate.
Drying a Protein Product
As shown in FIGURES 3 and 4, a process may include drying 370/470 a blanched
biomass or a solvent washed protein product to generate a protein concentrate
flake or a
protein concentrate granule 472 (e.g., first portion, second portion),
according to some
embodiments. A drying procedure, in some embodiments, may reduce a moisture
content of
a blanched biomass or a solvent washed protein product to a desired level
(e.g., lower
moisture content, a desired moisture content). A moisture content of a protein
concentrate
flake/granule may be, for example, below about 90%, or below about 80%, or
below about
70%, or below about 60%, or below about 50%, or below about 40%, or below
about 30%, or
below about 20%, or below about 10%, or below about 5%, or below about 1% by
weight of
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the protein concentrate flake/granule, in some embodiments. A drying procedure
may be
performed using a mechanism including, for example, a spray dryer, a drum
dryer, a double
drum dryer, flash dryer, a fluid-bed dryer, a convection dryer, an evaporator,
or any
combination thereof
In some embodiments, an inlet temperature of a dryer mechanism (the
temperature at
the entrance to a dryer) may be above 25 C, or above 50 C, or above 75 C,
or above
100 C, or above 125 C, or above 150 C, or above 175 C, or above 200 C, or
above
225 C, or above 250 C, or above 275 C, or above 300 C, or above 325 C, or
above
350 C, or above 375 C, or above 400 C, or above 425 C, or above 450 C, or
above
475 C, or above 500 C. An inlet temperature, in some embodiments, may be
from about
25 C to about 50 C, or from about 50 C to about 75 C, or from about 75 C
to about
100 C, or from about 100 C to about 125 C, or from about 125 C to about
150 C, or from
about 150 C to about 175 C, or from about 175 C to about 200 C, or from
about 200 C to
about 225 C, or from about 225 C to about 250 C, or from about 250 C to
about 275 C,
or from about 275 C to about 300 C, or from about 300 C to about 325 C, or
from about
325 C to about 350 C, or from about 350 C to about 375 C, or from about
375 C to about
400 C, or from about 400 C to about 425 C, or from about 425 C to about
450 C, or from
about 450 C to about 475 C, or from about 475 C to about 500 C, or above
500 C. An
inlet temperature may be from about 50 C to about 100 C, or from about 100
C to about
150 C, or from about 150 C to about 200 C, or from about 200 C to about
250 C, or from
about 250 C to about 300 C, or from about 300 C to about 350 C, or from
about 350 C to
about 400 C, or from about 400 C to about 450 C, or from about 450 C to
about 500 C,
or above 500 C, in some embodiments. According to some embodiments, an inlet
temperature of a dryer mechanism may be about 225 C.
According to some embodiments, an outlet temperature of a dryer mechanism (the
temperature at the exit from a dryer) may be below about 300 C, or below
about 275 C, or
below about 250 C, or below about 225 C, or below about 200 C, or below
about 175 C,
or below about 150 C, or below about 125 C, or below about 100 C, or below
about 75 C,
or below about 50 C, or below about 25 C. An outlet temperature may be from
about
300 C to about 275 C, or from about 275 C to about 250 C, or from about
250 C to about
225 C, or from about 225 C to about 200 C, or from about 200 C to about
175 C, or from
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about 175 C to about 150 C, or from about 150 C to about 125 C, or from
about 125 C to
about 100 C, or from about 100 C to about 75 C, or from about 75 C to
about 50 C, or
from about 50 C to about 25 C, or below about 25 C, in some embodiments. An
outlet
temperature, in some embodiments, may be from about 300 C to about 250 C, or
from
about 250 C to about 200 C, or from about 200 C to about 150 C, or from
about 150 C to
about 100 C, from about 100 C to about 50 C, or from about 50 C to about
25 C, or
below about 25 C. According to some embodiments, an outlet temperature of a
dryer
mechanism may be about 75 C.
In some embodiments, a volume of a blanched biomass or a volume of a solvent
washed protein product may be mixed with a volume of a protein concentrate
flake/granule
prior to drying. This process, known as back-mixing, may be employed when, for
example,
the moisture content of a blanched biomass exceeds the level that a dryer
mechanism is
capable of accepting. By back-mixing a protein concentrate flake/granule with
a blanched
biomass or a solvent washed protein product, a total moisture content may be
kept within the
specifications of a dryer mechanism, thereby reducing operational costs (e.g.,
wear and tear
on equipment).
Milling
As shown in FIGURE 4, according to some embodiments, a protein concentrate
flake/granule may be milled 474 to form a protein concentrate flour 476. A
milling
procedure may involve a hammer mill, a pin mill, a knife mill, a vibrating
mill, a fluid energy
mill, a jet mill, or any combination thereof A protein concentrate flour 476,
in some
embodiments, may have a particle size of less than 350 p.m, or less than 300
p.m, or less than
250 p.m, or less than 200 p.m, or less than 150 p.m, or less than 100 p.m, or
less than 90 p.m, or
less than 80 p.m, or less than 70 p.m, or less than 60 p.m, or less than 50
p.m, or less than 40
p.m, or less than 30 p.m, or less than 20 p.m, or less than 10 p.m.
An antioxidant (e.g., rosemary extract, Duralox , Phyt-O-Blend CA) may be
mixed
with a protein concentrate flake/granule or a protein concentrate flour before
packaging,
according to some embodiments.
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According to some embodiments, a blanched biomass, or a partially dried (e.g.,
having a reduced moisture content) blanched biomass, or a solvent washed
protein
concentrate may be frozen, flash-frozen, or freeze dried.
In some embodiments, a blanched biomass or a solvent washed protein
concentrate
may be milled prior to drying (e.g., a dry milled protein concentrate).
A Continuous Blanching Process
The present disclosure further relates to a method of continuously blanching a
biomass to generate a high-concentrate protein product (e.g., a protein
concentrate
flake/granule, a protein concentrate flour). In some embodiments, a method of
continuously
blanching a biomass may include: (a) blanching a first portion of the biomass
with a
blanching solution, (b) dewatering the first portion of the biomass to
generate a blanched
biomass and a separated solution, (c) collecting the separated solution, (d)
blanching a second
portion of the biomass with the separated solution, (e) dewatering the second
portion of the
biomass, (0 drying at least one of the first portion and the second portion of
the biomass to
generate at least one of a protein concentrate flake and a protein concentrate
granule. In some
embodiments, a protein concentrate flake and/or a protein concentrate granule
may be milled
to for a protein concentrate flour.
PROTEIN CONCENTRATE
Some embodiments relate to a process for production of a high-concentration
protein
product (e.g., a solvent washed protein concentrate, a protein concentrate
flake/granule, a
protein concentrate flour, a dry milled protein concentrate) from a biomass of
a harvested
microcrop (e.g., aquatic plant species, Lemna, algal species). A process may
be configured or
performed to achieve any desired protein yield (e.g., maximal yield, a
selected yield). In
some embodiments, a high-concentration protein product may have a protein
concentration of
at least about 35%, or at least about 40%, or at least about 45%, or at least
about 50%, or at
least about 60%, or at least about 65%, or at least about 70%, or at least
about 75%, or at least
about 80%, in each case, by dry mass basis (DMB). A remainder of a high-
concentration
protein product may include carbohydrates, fiber, fats, minerals, or any
combination thereof
A high-concentration protein product protein concentrate may be suitable for
animal feed
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and/or human consumption. For example, a high-concentration protein product
may serve as
an effective replacement for protein concentrates (e.g., soy, pea) which are
presently used in a
large number of human food products either individually or as ingredients and
additives.
According to some embodiments, at least of portion of a protein composition of
a high-
concentration protein product may comprise denatured or partially-denatured
protein.
Protein Digestibility Corrected Amino Acid Score (PDCASS) and Digestibility
According to some embodiments, a high-concentration protein product may have a
PDCASS relative to a reference standard (e.g., casein) of at least 0.88, or at
least 0.89, or at
least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least
0.94, or at least 0.95. In
some embodiments, a high-concentration protein product may have a PDCASS of
between
0.88 and 0.94, or between 0.90 and 0.94, or between 0.92 and 0.94. PDCASS may
be
evaluated, for example, by an animal (e.g., rat) model or by an in vitro
enzyme digestion
model. Calculating a PDCASS value may be dependent upon a limiting amino acid.
According to some embodiments, a PDCASS value of a high-concentration protein
product
may be limited by a histidine composition.
In some embodiments, a high-concentration protein product may have a
digestibility
of at least 88%, or at least 90%, or at least 92%, or at least 94%, or at
least 95%, or at least
96%, or at least 97%, or at least 98% in each case. Digestibility may be
determined, for
example, using a rat model (casein digestibility) or an in vitro digestibility
method (e.g.,
Animal-Safe Accurate Protein Quality Score (ASAP-Quality Score) method, TIM
model,
dynamic gastric model (DGM)).
Amino Acid Composition
In some embodiments, a high-concentration protein product may comprise one or
more essential amino acids. For example, a high-concentration protein product
may include
one or more amino acids selected from leucine, isoleucine, lysine, methionine,
phenylalanine,
threonine, tryptophan, valine, histidine, arginine, aspartic acid, serine,
glutamic acid, proline,
glycine, alanine, tyrosine and cysteine. The concentration of an essential
amino acid may be
at least about 1 g/100 g of protein concentrate, or at least about 1.5 g/100 g
of protein
concentrate, or at least about 2 g/100 g of protein concentrate, or at least
about 2.5 g/100 g of
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protein concentrate, or at least about 3 g/100 g of protein concentrate, or at
least about 4
g/100 g of dry at least about 2.5 g/100 g of protein concentrate, or at least
about 3 g/100 g of
protein concentrate, or at least about 4 g/100 g of protein concentrate, or at
least about 5 g/
100 g of protein concentrate, or at least about 6 g/100 g of protein
concentrate, or at least
about 7 g/100 g of protein concentrate, or at least about 8 g/100 g of protein
concentrate, or at
least about 9 g/100 g of protein concentrate, or at least about 10 g/100 g of
protein
concentrate in some embodiments.
The concentration of an amino acid (e.g., an essential amino acid), in some
embodiments, may be expressed as a weight fraction of the protein recovered
from a high-
concentration protein product, and is at least about 1 g/100 g of protein, or
at least about 1.5
g/100 g of protein, or at least about 2 g/100 g of protein, or at least about
2.5 g/100 g of
protein, or at least about 3 g/100 g of protein, or at least about 4 g/100 g
of protein, or at least
about 5 g/100 g of protein, or at least about 6 g/100 g of protein, or at
least about 7 g/100 g of
protein, or at least about 8 g/100 g of protein, or at least about 9 g/100 g
of protein, or at least
about 10 g/100 g of protein.
For example, a high-concentration protein product produced by the processes
described herein may include the amino acid contents summarized in Table 2
below.
TABLE 2: Amino Acid Profiles of High Concentration Protein Products (g/100 g
protein)
Amino Acid Product 1 Product 2
Tryptophan 2.1 2.1 + 10%
Alanine 4.8 4.8 + 10%
Arginine 5.7 5.7 + 10%
Aspartic Acid 7.8 7.8 + 10%
Glutamic Acid 9.4 9.4 + 10%
Gly cine 4.1 4.1 + 10%
Histidine 2.0 2.0 + 10%
Isoleucine 4.4 4.4 + 10%
Leucine 7.7 7.7 + 10%
Phenylalanine + 8.8 8.8 + 10%
Tyrosine
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Proline 3.9 3.9 + 10%
Serine 3.4 3.4 + 10%
Threonine 3.7 3.7 + 10%
Lysine 6.0 6.0 + 10%
Valine 5.3 5.3 + 10%
Cy steine + 2.9 2.9 + 10%
Methionine
Fat Content
In some embodiments, a high-concentration protein product may have a fat
content
lower than about 20%, or lower than about 15%, or lower than about 10%, or
lower than
about 8%, or lower than about 5%, or lower than about 4%, or lower than about
3%, or lower
than about 2%, or lower than about 1%, or lower than 0.5%, or lower than 0.4%,
or lower
than 0.3%, or lower than 0.2%, or lower than 0.1% by DMB of the protein
product. A high-
concentration protein product may have a fat content from about 1% to about
10%, or from
about 10% to about 20%, or from about 0.1% to about 10%, or from about 0.1% to
about 5%,
or from about 0.1% to about 2%, or from about 0.1% to about 1%, or from about
0.1% to
about 0.5% by DMB of the high-concentration protein product in some
embodiments. A
protein concentrate may be further processed to meet a desired fat content
(e.g., higher or
lower concentration, a desired fat composition).
Chlorophyll Content
According to some embodiments, a high-concentration protein product may have a
reduced chlorophyll content. In some embodiments, a high-concentration protein
product
may appear colorless or have reduced green coloration. A high-concentration
protein product
may have a chlorophyll content of less than 6,000 mg/100 g, or less than 5,500
mg/100 g, or
less than 5,000 mg/100 g, or less than 4,500 mg/100 g, or less than 4,000
mg/100 g, or less
than 3,500 mg/100 g, or less than 3,000 mg/100 g.
Apiogalacturonan and/or Oligogalacturan Content
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In some embodiments, a high-concentration protein product may include at least
one
apiogalacturonan and/or oligogalacturonide. According to some embodiments, a
high-
concentration protein product polysaccharide product may have a concentration
of at least
one apiogalacturonan of at least 1% DMB, or at least 3% DMB, or at least 5%
DMB, or at
least 7% DMB, or at least 10% DMB, or at least 12% DMB, or at least 15% DMB,
or at least
20% DMB, or at least 25% DMB, or at least 30% DMB. A high-concentration
protein
product, in some embodiments, may have a concentration of at least one
apiogalacturonan of
at least 10% DMB. In some embodiments, a polysaccharide product may have a
concentration of at least one apiogalacturonan of at least 15% DMB.
Concentrations recited
in this paragraph may refer to a single apiogalacturonan or to the combined
(total)
concentration of two or more (up to all) apiogalacturonans present, according
to some
embodiments.
According to some embodiments, a concentration of at least one
apiogalacturonan
and/or oligogalacturonide in a high-concentration protein product may be
determined by a
phenol-sulfuric acid method, such as that described in Dubois, M., Gilles,
K.A., Hamilton,
J.K., et al., Anal. Chem., 1956, vol. 28, no. 2, 350-356. A concentration of
at least one
apiogalacturonan and/or oligogalacturonide in a high-concentration protein
product may be
determined using UV spectrophotometry, such as that described in Albalasmeh,
A., Berhe,
A., and Ghezzeher, T., Carbohydrate Polymers, 2013, vol. 97, no. 2, 253-261,
in some
embodiments. Any desired method may be used to determine a concentration of at
least one
apiogalacturonan and/or oligogalacturonide in a high-concentration protein
product.
A monosaccharide composition of a concentration of a high-concentration
protein
product may be determined by high pressure anion exchange chromatography
(HPAEC),
according to some embodiments. For example, HPAEC may be performed using a
Dionex
CarboPac PA1 column with amperometric detection of polysaccharide hydrolysis
where
hydrolysis was performed under the following conditions: (1) hydrolysis with
2N
Trifluoracetic acid (TFA) at 100 C for 0.5 hours; (2) hydrolysis with 2N TFA
at 100 C for 4
hours; (3) hydrolysis with 2N H2SO4 at 100 C for 6 hours; (4) hydrolysis with
2N H2SO4 at
100 C for 6 hours after overnight exposure to 26N H2SO4 at room temperature.
In some embodiments, a monosaccharide composition of a high-concentration
protein
product may be determined by gas phase chromatography. For example, the
relative
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composition of a monosaccharide of a high-concentration protein product may be
identified
and quantified by (1) hydrolyzing the product to form monosaccharides by
methaolysis; (2)
trimethylsilying the monosaccharides to form volatilized monosaccharides; and
(3)
quantifying and identifying the volatilized monosaccharides as 0-
methylglycosides by gas
phase chromatography.
Oxalic Acid Content
According to some embodiments, a high-concentration protein product may have a
reduced oxalic acid (H2C204 or HOOCCOOH) content. In some embodiments, a high-
concentration protein product may have an oxalic acid content of lower than
about 1.5%, or
lower than about 1.4%, or lower than about 1.3%, or lower than about 1.2%, or
lower than
about 1.1%, or lower than about 1.0%, or lower than about 0.9%, or lower than
about 0.8%,
or lower than about 0.75%, or lower than about 0.7%, or lower than about
0.65%, or lower
than about 0.6%, lower than about 0.55%, lower than about 0.5%, or lower than
about 0.45%,
or lower than about 0.4%, or lower than about 0.35%, or lower than about 0.3%,
or lower
than about 0.25%, or lower than about 0.2%, or lower than about 0.15%, or
lower than about
0.1%, or lower than about 0.05%, or lower than about 0.04%, or lower than
about 0.03%, or
lower 0.02% by DMB. A high-concentration protein product, in some embodiments
may
have an oxalic acid content of from about 0.02% to about 0.6%, from about
0.02% to about
0.5%, or from about 0.02% to about 0.4%, or from about 0.02% to about 0.3%, or
from about
0.02% to about 0.2%, or from about 0.02% to about 0.15%, or from about 0.02%
to about
0.1% by DMB. In some embodiments, a high-concentration protein product may
have an
oxalic acid content of no more than 0.1%. According to some embodiments, a
high-
concentration protein product may have an oxalic acid content of no more than
0.05% DMB.
Polyphenol Content
In some embodiments, a high-concentration protein product may be reduced in at
least
one polyphenol (e.g., tannin). In some embodiments, a high-concentration
protein product
(e.g., a solvent washed protein concentrate, a protein concentrate
flake/granule, a protein
concentrate flour), may comprise polyphenol (e.g., total soluble polyphenol)
at a
concentration (mg/100 g of high-concentration protein product) of less than
about 1.5 mg/100
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g, or less than about 1.55 mg/100 g, or less than about 1.6 mg/100 g, or less
than about 1.65
mg/100 g, or less than about 1.7 mg/100 g, or less than about 1.75 mg/100 g,
or less than
about 1.8 mg/100 g, or less than about 1.85 mg/100 g, or less than about 1.9
mg/100 g, or less
than about 2.0 mg/100 g, or less than about 2.2 mg/100 g, or less than about
2.4 mg/100 g, or
less than about 2.6 mg/100 g, or less than about 2.8 mg/100 g, or less than
about 3.0 mg/100
g, or less than about 3.2 mg/100 g.
Ash Content
According to some embodiments, a high-concentration protein product may
include
an ash content consisting of a residue containing inorganic mineral elements.
An ash content
in some embodiments may be determined by combusting a protein product at a
high
temperature (e.g., > 500 C) to remove organic matter. A high-concentration
protein product
may have an ash content lower than about 50%, or lower than about 40%, or
lower than about
30%, or lower than about 25%, or lower than about 20%, or lower than about
15%, or lower
than about 10%, or lower than about 5%, or lower than about 4%, or lower than
about 3%, or
lower than about 2%, or lower than about 1% by DMB of the protein product, in
some
embodiments. A high-concentration protein concentrate may be further processed
to meet a
desired ash content (e.g., higher or lower concentration, a desired ash
composition),
according to some embodiments.
Carbohydrate Content
According to some embodiments, a high-concentration protein product may have a
carbohydrate content (e.g., pectin) lower than about 50%, or lower than about
40%, or lower
than about 30%, or lower than about 25%, or lower than about 20%, or lower
than about
15%, or lower than about 10%, or lower than about 5%, or lower than about 4%,
or lower
than about 3%, or lower than about 2%, or lower than about 1% by DMB of the
protein
product. A high-concentration protein product, in some embodiments, may have a
carbohydrate content from about 1% to about 10%, or from about 10% to about
20%, or from
about 20% to about 30%, or from about 30% to about 40%, or from about 40% to
about 50%
by DMB of the protein product. In some embodiments, a high-concentration
protein product
may have a carbohydrate content from about 1% to about 50%, or from about 2%
to about
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40%, or from about 5% to about 30%, or from about 8% to about 20%, or from
about 10% to
about 15% by DMB of the protein product. A high-concentration protein product
may be
further processed to meet a desired carbohydrate content (e.g., higher or
lower concentration,
a desired carbohydrate composition).
Dietary Fiber Content
In some embodiments, a high-concentration protein product may have a dietary
fiber
content of at least about 20% DMB, or at least about 25%, or at least about
30%, or at least
about 35%, or at least about 40%, or at least about 45%, or at least about
50%, where "about"
may represent plus or minus 3%. According to some embodiments, a high-
concentration
protein product may have a dietary fiber content between about 20% and about
45%, or
between about 30% and about 45%, or between about 35% and about 45%, where
"about"
may represent plus or minus 3%. A high-concentration protein product may be
further
processed to meet a desired dietary fiber content (e.g., higher or lower
concentration, a
desired dietary fiber composition).
Water-Binding Capacity
In some embodiments, a high-concentration protein product may have a water-
binding
capacity of about 4 milliliters of water per gram of high-concentration
protein product (ml/g),
or about 4.5 ml/g, or about 5.0 ml/g, or about 6.0 ml/g, or about 7.0 ml/g, or
about 7.5 ml/g,
or about 8.0 ml/g, or about 8.5 ml/g, or about 9.0 ml/g, or about 9.5 ml/g, or
about 10.0 ml/g.
According to some embodiments, a high-concentration protein product may have a
water
binding capacity of at least 4 ml/g, or at least 5 ml/g, or at least 6 ml/g,
or at least 7 ml/g, or at
least 7.5 ml/g, or at least 8 ml/g, or at least 8.5 ml/g, or at least 9 ml/g,
or at least 9.5 ml/g.
Oil-Binding Capacity
In some embodiments, a high-concentration protein product may have an oil-
binding
capacity (e.g., corn oil) of about 2 milliliters of oil (e.g., corn oil) per
gram of high-
concentration protein product (ml/g), or about 2.5 ml/g, or about 3.0 ml/g, or
about 3.5 ml/g,
or about 4.0 ml/g, or about 4.5 ml/g, or about 5.0 ml/g, or about 5.5 ml/g.
According to some
embodiments, a high-concentration protein product may have a water binding
capacity of at
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least 2 ml/g, or at least 2.5 ml/g, or at least 3.0 ml/g, or at least 3.5
ml/g, or at least 4.0 ml/g,
or at least 4.5 ml/g, or at least 5.0 ml/g, or at least 5.5 ml/g. For example,
a high-
concentration protein product produced by the processes described herein may
include the
contents summarized in Table 3 below.
TABLE 3: Example Compositions of High-Concentration Protein Products
Characteristic Product 1 Product 2
Product 3 Product 4
Solids (DMB) > 90 88-95 > 90 88-95
Moisture (DMB) <10 5-12 < 10 5-12
Protein (DMB) > 50 50-65 > 45 35-45
PDCASS > 0.90 0.88-0.94 > 0.90 0.88-
0.94
PDCASS Limiting Amino Acid Histidine Histidine
Histidine Histidine
Digestibility > 0.90 0.85-0.96 > 0.90 0.85-
0.96
Fat (DMB) < 1 0.05-1.5 < 10 5-10
Ash (DMB) < 10 5-15 < 10 5-15
Dietary Fiber (DMB) >40
35-45 > 40
35-45
Other carbohydrates (DMB) < 5 1-10 <5 5-10
Oxalic acid < 1.5 0.2-2.5 <1 0.2-2.0
Any desired method may be used to determine a composition of a high-
concentration
protein product.
A product and/or process, in some embodiments, may be configured or performed
so
other characteristics of a high-concentration protein product (e.g., particle
size, bacterial
specification) meet desired criteria and/or may be suitable for an intended
purpose.
In some embodiments, a high-concentration protein product may be packed and/or
sealed in either an industry standard bag or drum of varying sizes. A sealing
method of
industry-standard grade may be used to ensure proper shelf-life and shipping
conditions. A
bag or drum may include printed instructions or specifications regarding, for
example, its
intended use, shelf-life, suggested storage conditions, shipping conditions,
compositions, or
the like, or a combination thereof An antioxidant (e.g., rosemary extract,
Duralox , Phyt-0-
Blend CA) may be mixed with a protein product before drying or packaging,
according to
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some embodiments. According to some embodiments, lecithin may be mixed with a
wet
protein product prior to drying to improve a mouth-feel of a product.
Various changes may be made in the shape, size, number, separation
characteristic,
and/or arrangement of parts without departing from the scope of the instant
disclosure. Each
disclosed method and method step may be performed in association with any
other disclosed
method or method step and in any order according to some embodiments. Where
the verb
"may" appears, it is intended to convey an optional and/or permissive
condition, but its use is
not intended to suggest any lack of operability unless otherwise indicated.
Various changes
may be made in methods of preparing and using a composition, device, and/or
system of the
disclosure without departing from the scope of the instant disclosure. Where
desired, some
embodiments of the disclosure may be practiced to the exclusion of other
embodiments.
Also, where ranges have been provided, the disclosed endpoints may be treated
as
exact and/or approximations as desired or demanded by the particular
embodiment. Where
the endpoints are approximate, the degree of flexibility may vary in
proportion to the order of
magnitude of the range. For example, on one hand, a range endpoint of about 50
in the
context of a range of about 5 to about 50 may include 50.5, but not 52.5 or 55
and, on the
other hand, a range endpoint of about 50 in the context of a range of about
0.5 to about 50
may include 55, but not 60 or 75. In some embodiments, the degree of
flexibility may simply
be a specific percentage of the disclosed end point (e.g., 1% where tight
control of end
point values is desirable, 10% where end point values are flexible and/or
vary according to
other parameters). In addition, it may be desirable, in some embodiments, to
mix and match
range endpoints. Also, in some embodiments, each figure disclosed (e.g., in
one or more of
the examples, tables, and/or drawings) may form the basis of a range (e.g.,
depicted value +/-
about 10%, depicted value +/- about 50%, depicted value +/- about 100%) and/or
a range
endpoint. With respect to the former, a value of 50 depicted in an example,
table, and/or
drawing may form the basis of a range of, for example, about 45 to about 55,
about 25 to
about 100, and/or about 0 to about 100. Unless otherwise designated within
this disclosure,
percentages as applied to concentrations are percentages on a dry mass basis
(DMB).
These equivalents and alternatives along with obvious changes and
modifications are
intended to be included within the scope of the present disclosure.
Accordingly, the
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foregoing disclosure is intended to be illustrative, but not limiting, of the
scope of the
disclosure as illustrated by the appended claims.
The title, abstract, background, and headings are provided in compliance with
regulations
and/or for the convenience of the reader. They include no admissions as to the
scope and
content of prior art and no limitations applicable to all disclosed
embodiments.
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EXAMPLES
Some specific example embodiments of the disclosure may be illustrated by one
or
more of the examples provided herein.
EXAMPLE 1: Continuous Blanching of Lemna to Generate a High Concentration
Protein
Product
Various blanching conditions were tested for their impact on multiple
characteristics
of a high-protein concentrate product. Lemna was cultivated in a growth medium
including
water and nutrients. The Lemna was harvested and conveyed to a continuous
blanching
apparatus including: a conveyor mechanism, a blanching tray connected to a
vibratory
mechanism capable of vibrating the blanching tray and generating a net motion
in the
blanching solution within blanching tray, a shower, a dewatering mechanism of
a vibratory
screen and screw press, a fluid bed dryer, and a pin mill.
The blanching apparatus was run at a product flow rate ratio of 7:1. Lots of
400-600
kg of Lemna were run through the continuous blanching system at a Lemna feed
rate of 4
kg/minute. A pump rate was set at 28 L/min. Each lot was conveyed to the
blanching tray
where it was showered with a blanching solution having a temperature of
between 92 C and
94 C as it exited the shower. Simultaneously, the vibratory mechanism
generated waves in
the blanching solution pooled in the blanching tray. The system was adjusted
to maintain a
contact time between blanching liquid and Lemna of 45 seconds. Following
blanching for 45
seconds, each lot was dewatered using a vibratory screen and a screw press.
The separated
blanching solution was collected and diluted with fresh water in a dilution
ratio of 2.4:1 (i.e.,
9.6 L/m). A fluid bed dryer was used to dry each lot to a moisture content of
about 10% to
form a protein concentrate flake. The protein concentrate flake was milled
using a pin mill to
form a protein concentrate flour.
Compositional analysis was performed on the protein concentrate flour
generated
from the various lots. The average amino acid profile of the Lemna samples is
found in Table
2. Average composition characteristics of the protein flour samples is found
in Table 3. In
the protein concentrate samples tested, the oxalic acid concentration of was
<0.25% and the
soluble polyphenol concentration was < 3.2 mg/100 g. In most cases, the
soluble polyphenol
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concentration was found to be below the detectable limits of the test. Table 4
depicts the
average nutritional information of the Lemna protein concentrate flour
samples.
TABLE 2: Amino Acid Profile of Lemna Protein Concentrate Flour
Amino Acid Profile (g/100 g protein concentrate flake)
Try ptophan 2.1
Alanine 4.8
Arginine 5.7
Aspartic Acid 7.8
Glutamic Acid 9.4
Glycine 4.1
Histidine 2.0
Isoleucine 4.4
Leucine 7.7
Phenylalanine + Tyrosine 8.8
Proline 3.9
Serine 3.4
Threonine 3.7
Lysine 6.0
Valine 5.3
Cysteine + Methionine 2.9
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TABLE 3: Compositions of Protein Concentrate Flour
Characteristic
Solids (DMB) ¨ 92
Moisture (DMB) <8
Protein (DMB) 45-50
PDCASS 0.93
Digestibility > 90
Fat (DMB) < 7
Ash (DMB) <10
Fiber (DMB) 35-45
Oxalic acid <1
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TABLE 4. Average nutritional information of Lemna protein concentrate flour
TRAIT UNIT (per 100 g) DMB %
Moisture % 2.77
Ash % 6.18 6.4%
Calories Kcal 449
Calories From Fat 69.30
Protein % 48.05 49.4%
Carbohydrates % 46.9 48.2%
Dietary Fiber % 39.85 41.0%
Sugars % 0 0.0%
Total Fat (AH) % 7.70 7.9%
Total Fat Acid Content % 6.99 7.2%
Saturated Fat % 1.51 1.6%
Monounsaturated % 0.15 0.2%
Polyunsaturated % 4.79 4.9%
Trans Fat % 0.23 0.2%
Cholesterol mg/100 g 0.84
Sodium mg/100 g 133
Vitamin A (B-Carotene) IU/100 g 56200
Vitamin C mg/100 g
Calcium mg/100 g 1300
Iron mg/100 g 37
Vitamin E IU/100 g 12
Thiamine (B1) mg/100 g 0.03
Riboflavin (B2) mg/100 g 0.65
Niacin (B3) mg/100 g 0.537
Pantothenic acid (B5) mg/100 g 0.02
Vitamin B6 mg/100 g 0.275
Folic acid (B9) mg/100 g 229.91
Potassium mg/100 g 54.1
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TRAIT UNIT (per 100 g) % DMB
Magnesium mg/100 g 343
Zinc mg/100 g 10.3
Copper mg/100 g <1
Manganese mg/100 g 39.7
Phosphorus mg/100 g 640
Aluminum ppm 2.656
Boron ppm 643.797
Barium ppm 1.365
Cobalt ppm 0.01
Chromium ppm 0.296
Molybdenum ppm 0.53
Nickel ppm 0.1
Selenium ppm 0.01
Chlorophyll mg/100 g 540 0.56%
Lutein mg/100 g 38.5 0.0396%
Total polyphenols mg GAE/kg 3.244 0.0033%
